Durability features for end effectors and firing assemblies of surgical stapling instruments

ABSTRACT

A surgical instrument includes an end effector that has a staple cartridge having staples, and an anvil including staple forming pockets. The surgical instrument further includes a firing assembly movable to cause the staples to be deformed against the forming pockets. The firing assembly includes a firing member having a first engagement member configured to movably engage the anvil, and a second engagement member configured to movable engage the staple cartridge to transition the end effector to the closed configuration. The firing assembly also includes a laminated firing bar that has a first outer layer, a second outer layer, and an intermediate layer sandwiched between the first outer layer and the second outer layer, wherein the intermediate layer is thicker than the first outer layer, and wherein the intermediate layer is thicker than the second outer layer.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein are set forth withparticularity in the appended claims. The various embodiments, however,both as to organization and methods of operation, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of a staple for use with a surgicalstapling instrument in accordance with at least one embodiment;

FIG. 2 is a side elevation view of the staple of FIG. 1;

FIG. 3 is a top view of the staple of FIG. 1;

FIG. 4 is a cross-sectional view of the staple of FIG. 1 taken alongline 4-4 in FIG. 3;

FIG. 5 is a perspective view of a staple cartridge assembly inaccordance with at least one embodiment;

FIG. 6 is a plan view of the staple cartridge assembly of FIG. 5 withouta bottom pan;

FIG. 7 is a cross-sectional view of an end effector including a staplecartridge assembly and an anvil in accordance with at least oneembodiment;

FIG. 8 is a cross-sectional view of a sled of the end effector of FIG.7;

FIG. 9 is an elevational view of staples with different unformed heightsin accordance with at least one embodiment;

FIG. 10 is an elevational view of staples with different formed heightsin accordance with at least one embodiment;

FIG. 11 is an elevational view of staples with different formed heightsin accordance with at least one embodiment;

FIG. 12 is a perspective view of a staple cartridge assembly includingtissue retention features in accordance with at least one embodiment;

FIG. 13 is a top view of the staple cartridge assembly of FIG. 12;

FIG. 14 is a top view of a staple cartridge assembly including tissueretention features in accordance with at least one embodiment;

FIG. 15 is a top view of a staple cartridge assembly including gapsetting members in accordance with at least one embodiment;

FIG. 16 is a cross-sectional view of an end effector including a staplecartridge assembly and an anvil in accordance with at least oneembodiment;

FIG. 17 is a longitudinal cross-sectional view of an end effectorincluding a staple cartridge assembly and an anvil in accordance with atleast one embodiment;

FIG. 18 is a perspective view of a staple cartridge assembly includinggap setting pins in accordance with at least one embodiment;

FIG. 19 is a perspective view of a staple cartridge assembly includinggap setting features in accordance with at least one embodiment;

FIG. 20 is a perspective view of a staple cartridge assembly including astaple cartridge and a staple retainer held against a cartridge deck ofthe staple cartridge by a hairpin retainer;

FIG. 21 is an exploded view of the staple cartridge assembly of FIG. 20;

FIG. 22 is a cross-sectional view of the staple cartridge assembly ofFIG. 20 where the hairpin retainer is fully inserted into an elongateslot of the staple cartridge;

FIG. 23 is a cross-sectional view of the staple cartridge assembly ofFIG. 20 where the hairpin retainer is partially inserted into theelongate slot of the staple cartridge;

FIG. 24 is a perspective view of a staple cartridge assembly includingstepped deck surfaces in accordance with at least one embodiment;

FIG. 25 is a plan view of the staple cartridge assembly of FIG. 24without a bottom pan;

FIG. 26 is a perspective view of a quadruple staple driver of the staplecartridge assembly of FIG. 25;

FIG. 27 is a partial perspective view of the staple cartridge assemblyof FIG. 24;

FIG. 28 is a cross-sectional view as taken along the lines 28-28, ofFIG. 27;

FIG. 29 is a perspective view of a quadruple staple driver includingdeformable retention features in accordance with at least oneembodiment;

FIG. 30 is a partial perspective view of a staple cartridge assemblyincluding deformable retention features in accordance with at least oneembodiment;

FIG. 31 is a cross-sectional view as taken along the lines 31-31, ofFIG. 30;

FIG. 32 is a plan view of a staple cavity of the staple cartridgeassembly of FIG. 30;

FIG. 33 is a partial perspective view of an anvil of a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 34 is a partial perspective view of an anvil of a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 35 is a partial perspective view of a firing assembly and a firingbar of a surgical stapling and cutting instrument in accordance with theat least one embodiment;

FIG. 36 is a partial perspective view of the firing bar of FIG. 35;

FIG. 37 is a cross-sectional view of a firing bar of a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 38 is a cross-sectional view of a firing bar of a surgical staplingand cutting instrument in accordance with at least one embodiment;

FIG. 39 is a cross-sectional view of an end effector of a surgicalstapling and cutting instrument in a closed configuration;

FIG. 40 is a cross-sectional view of the end effector of FIG. 39 in anopen configuration;

FIG. 41 is a cross-sectional view of an end effector of a surgicalstapling and cutting instrument in a closed configuration;

FIG. 42 is a cross-sectional view of the end effector of FIG. 41 in anopen configuration;

FIG. 43 is an elevational view of a disposable loading unit inaccordance with at least one embodiment;

FIG. 44 is an elevational view of a disposable loading unit inaccordance with at least one embodiment;

FIG. 45 is an elevational view of a disposable loading unit inaccordance with at least one embodiment; and

FIG. 46 is an exploded view of an intermediate shaft assembly inaccordance with at least one embodiment.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/386,185, entitled SURGICAL STAPLINGINSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF;

U.S. patent application Ser. No. 15/386,230, entitled ARTICULATABLESURGICAL STAPLING INSTRUMENTS;

U.S. patent application Ser. No. 15/386,221, entitled LOCKOUTARRANGEMENTS FOR SURGICAL END EFFECTORS;

U.S. patent application Ser. No. 15/386,209, entitled SURGICAL ENDEFFECTORS AND FIRING MEMBERS THEREOF;

U.S. patent application Ser. No. 15/386,198, entitled LOCKOUTARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL ASSEMBLIES;and

U.S. patent application Ser. No. 15/386,240, entitled SURGICAL ENDEFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,939, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN;

U.S. patent application Ser. No. 15/385,941, entitled SURGICAL TOOLASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN CLOSURESYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND ARTICULATION ANDFIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,943, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS;

U.S. patent application Ser. No. 15/385,950, entitled SURGICAL TOOLASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES;

U.S. patent application Ser. No. 15/385,945, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN;

U.S. patent application Ser. No. 15/385,946, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS;

U.S. patent application Ser. No. 15/385,951, entitled SURGICALINSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW OPENINGDISTANCE;

U.S. patent application Ser. No. 15/385,953, entitled METHODS OFSTAPLING TISSUE;

U.S. patent application Ser. No. 15/385,954, entitled FIRING MEMBERSWITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL END EFFECTORS;

U.S. patent application Ser. No. 15/385,955, entitled SURGICAL ENDEFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS;

U.S. patent application Ser. No. 15/385,948, entitled SURGICAL STAPLINGINSTRUMENTS AND STAPLE-FORMING ANVILS;

U.S. patent application Ser. No. 15/385,956, entitled SURGICALINSTRUMENTS WITH POSITIVE JAW OPENING FEATURES;

U.S. patent application Ser. No. 15/385,958, entitled SURGICALINSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING SYSTEMACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT;

U.S. patent application Ser. No. 15/385,947, entitled STAPLE CARTRIDGESAND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES THEREIN.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,896, entitled METHOD FORRESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT;

U.S. patent application Ser. No. 15/385,898, entitled STAPLE FORMINGPOCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF STAPLES;

U.S. patent application Ser. No. 15/385,899, entitled SURGICALINSTRUMENT COMPRISING IMPROVED JAW CONTROL;

U.S. patent application Ser. No. 15/385,901, entitled STAPLE CARTRIDGEAND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS DEFINED THEREIN;

U.S. patent application Ser. No. 15/385,902, entitled SURGICALINSTRUMENT COMPRISING A CUTTING MEMBER;

U.S. patent application Ser. No. 15/385,904, entitled STAPLE FIRINGMEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT CARTRIDGE LOCKOUT;

U.S. patent application Ser. No. 15/385,905, entitled FIRING ASSEMBLYCOMPRISING A LOCKOUT;

U.S. patent application Ser. No. 15/385,907, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A FIRINGASSEMBLY LOCKOUT;

U.S. patent application Ser. No. 15/385,908, entitled FIRING ASSEMBLYCOMPRISING A FUSE; and

U.S. patent application Ser. No. 15/385,909, entitled FIRING ASSEMBLYCOMPRISING A MULTIPLE FAILED-STATE FUSE.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,920, entitled STAPLE FORMINGPOCKET ARRANGEMENTS;

U.S. patent application Ser. No. 15/385,913, entitled ANVIL ARRANGEMENTSFOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/385,914, entitled METHOD OFDEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES WITH THESAME SURGICAL STAPLING INSTRUMENT;

U.S. patent application Ser. No. 15/385,893, entitled BILATERALLYASYMMETRIC STAPLE FORMING POCKET PAIRS;

U.S. patent application Ser. No. 15/385,929, entitled CLOSURE MEMBERSWITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS WITH SEPARATE ANDDISTINCT CLOSURE AND FIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,911, entitled SURGICAL STAPLERSWITH INDEPENDENTLY ACTUATABLE CLOSING AND FIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,927, entitled SURGICAL STAPLINGINSTRUMENTS WITH SMART STAPLE CARTRIDGES;

U.S. patent application Ser. No. 15/385,917, entitled STAPLE CARTRIDGECOMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS;

U.S. patent application Ser. No. 15/385,900, entitled STAPLE FORMINGPOCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND POCKET SIDEWALLS;

U.S. patent application Ser. No. 15/385,931, entitled NO-CARTRIDGE ANDSPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/385,915, entitled FIRING MEMBER PINANGLE;

U.S. patent application Ser. No. 15/385,897, entitled STAPLE FORMINGPOCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE GROOVES;

U.S. patent application Ser. No. 15/385,922, entitled SURGICALINSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES;

U.S. patent application Ser. No. 15/385,924, entitled SURGICALINSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS;

U.S. patent application Ser. No. 15/385,912, entitled SURGICALINSTRUMENTS WITH JAWS THAT ARE PIVOTABLE ABOUT A FIXED AXIS AND INCLUDESEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS;

U.S. patent application Ser. No. 15/385,910, entitled ANVIL HAVING AKNIFE SLOT WIDTH;

U.S. patent application Ser. No. 15/385,903, entitled CLOSURE MEMBERARRANGEMENTS FOR SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 15/385,906, entitled FIRING MEMBER PINCONFIGURATIONS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/386,188, entitled STEPPED STAPLECARTRIDGE WITH ASYMMETRICAL STAPLES;

U.S. patent application Ser. No. 15/386,192, entitled STEPPED STAPLECARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES;

U.S. patent application Ser. No. 15,386,206, entitled STAPLE CARTRIDGEWITH DEFORMABLE DRIVER RETENTION FEATURES;

U.S. patent application Ser. No. 15/386,222, entitled SURGICAL STAPLINGINSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING FEATURES; and

U.S. patent application Ser. No. 15/386,236, entitled CONNECTIONPORTIONS FOR DISPOSABLE LOADING UNITS FOR SURGICAL STAPLING INSTRUMENTS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,887, entitled METHOD FORATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND, ALTERNATIVELY,TO A SURGICAL ROBOT;

U.S. patent application Ser. No. 15/385,889, entitled SHAFT ASSEMBLYCOMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR USE WITH AMOTORIZED SURGICAL INSTRUMENT SYSTEM;

U.S. patent application Ser. No. 15/385,890, entitled SHAFT ASSEMBLYCOMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE SYSTEMS;

U.S. patent application Ser. No. 15/385,891, entitled SHAFT ASSEMBLYCOMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A ROTARY FIRINGMEMBER TO TWO DIFFERENT SYSTEMS;

U.S. patent application Ser. No. 15/385,892, entitled SURGICAL SYSTEMCOMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION STATE TOARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM;

U.S. patent application Ser. No. 15/385,894, entitled SHAFT ASSEMBLYCOMPRISING A LOCKOUT; and

U.S. patent application Ser. No. 15/385,895, entitled SHAFT ASSEMBLYCOMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/385,916, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,918, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,919, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,921, entitled SURGICAL STAPLECARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED TO DISENGAGE FIRINGMEMBER LOCKOUT FEATURES;

U.S. patent application Ser. No. 15/385,923, entitled SURGICAL STAPLINGSYSTEMS;

U.S. patent application Ser. No. 15/385,925, entitled JAW ACTUATED LOCKARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A FIRING MEMBER IN A SURGICALEND EFFECTOR UNLESS AN UNFIRED CARTRIDGE IS INSTALLED IN THE ENDEFFECTOR;

U.S. patent application Ser. No. 15/385,926, entitled AXIALLY MOVABLECLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS TO JAWS OFSURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/385,928, entitled PROTECTIVE COVERARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW AND ACTUATORSHAFT OF A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 15/385,930, entitled SURGICAL ENDEFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR OPENING ANDCLOSING END EFFECTOR JAWS;

U.S. patent application Ser. No. 15/385,932, entitled ARTICULATABLESURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT ARRANGEMENT;

U.S. patent application Ser. No. 15/385,933, entitled ARTICULATABLESURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE LINKAGE DISTAL OF ANARTICULATION LOCK;

U.S. patent application Ser. No. 15/385,934, entitled ARTICULATION LOCKARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN ARTICULATED POSITION INRESPONSE TO ACTUATION OF A JAW CLOSURE SYSTEM;

U.S. patent application Ser. No. 15/385,935, entitled LATERALLYACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR OFA SURGICAL INSTRUMENT IN AN ARTICULATED CONFIGURATION; and

U.S. patent application Ser. No. 15/385,936, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH ARTICULATION STROKE AMPLIFICATION FEATURES.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/191,775, entitled STAPLE CARTRIDGECOMPRISING WIRE STAPLES AND STAMPED STAPLES;

U.S. patent application Ser. No. 15/191,807, entitled STAPLING SYSTEMFOR USE WITH WIRE STAPLES AND STAMPED STAPLES;

U.S. patent application Ser. No. 15/191,834, entitled STAMPED STAPLESAND STAPLE CARTRIDGES USING THE SAME;

U.S. patent application Ser. No. 15/191,788, entitled STAPLE CARTRIDGECOMPRISING OVERDRIVEN STAPLES; and

U.S. patent application Ser. No. 15/191,818, entitled STAPLE CARTRIDGECOMPRISING OFFSET LONGITUDINAL STAPLE ROWS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. Design patent application Ser. No. 29/569,218, entitled SURGICALFASTENER;

U.S. Design patent application Ser. No. 29/569,227, entitled SURGICALFASTENER;

U.S. Design patent application Ser. No. 29/569,259, entitled SURGICALFASTENER CARTRIDGE; and

U.S. Design patent application Ser. No. 29/569,264, entitled SURGICALFASTENER CARTRIDGE.

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/089,325, entitled METHOD FOROPERATING A SURGICAL STAPLING SYSTEM;

U.S. patent application Ser. No. 15/089,321, entitled MODULAR SURGICALSTAPLING SYSTEM COMPRISING A DISPLAY;

U.S. patent application Ser. No. 15/089,326, entitled SURGICAL STAPLINGSYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE DISPLAY FIELD;

U.S. patent application Ser. No. 15/089,263, entitled SURGICALINSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;

U.S. patent application Ser. No. 15/089,262, entitled ROTARY POWEREDSURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT SYSTEM;

U.S. patent application Ser. No. 15/089,277, entitled SURGICAL CUTTINGAND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE MEMBER;

U.S. patent application Ser. No. 15/089,296, entitled INTERCHANGEABLESURGICAL TOOL ASSEMBLY WITH A SURGICAL END EFFECTOR THAT IS SELECTIVELYROTATABLE ABOUT A SHAFT AXIS;

U.S. patent application Ser. No. 15/089,258, entitled SURGICAL STAPLINGSYSTEM COMPRISING A SHIFTABLE TRANSMISSION;

U.S. patent application Ser. No. 15/089,278, entitled SURGICAL STAPLINGSYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF TISSUE;

U.S. patent application Ser. No. 15/089,284, entitled SURGICAL STAPLINGSYSTEM COMPRISING A CONTOURABLE SHAFT;

U.S. patent application Ser. No. 15/089,295, entitled SURGICAL STAPLINGSYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT;

U.S. patent application Ser. No. 15/089,300, entitled SURGICAL STAPLINGSYSTEM COMPRISING AN UNCLAMPING LOCKOUT;

U.S. patent application Ser. No. 15/089,196, entitled SURGICAL STAPLINGSYSTEM COMPRISING A JAW CLOSURE LOCKOUT;

U.S. patent application Ser. No. 15/089,203, entitled SURGICAL STAPLINGSYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT;

U.S. patent application Ser. No. 15/089,210, entitled SURGICAL STAPLINGSYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT;

U.S. patent application Ser. No. 15/089,324, entitled SURGICALINSTRUMENT COMPRISING A SHIFTING MECHANISM;

U.S. patent application Ser. No. 15/089,335, entitled SURGICAL STAPLINGINSTRUMENT COMPRISING MULTIPLE LOCKOUTS;

U.S. patent application Ser. No. 15/089,339, entitled SURGICAL STAPLINGINSTRUMENT;

U.S. patent application Ser. No. 15/089,253, entitled SURGICAL STAPLINGSYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES HAVING DIFFERENTHEIGHTS;

U.S. patent application Ser. No. 15/089,304, entitled SURGICAL STAPLINGSYSTEM COMPRISING A GROOVED FORMING POCKET;

U.S. patent application Ser. No. 15/089,331, entitled ANVIL MODIFICATIONMEMBERS FOR SURGICAL STAPLERS;

U.S. patent application Ser. No. 15/089,336, entitled STAPLE CARTRIDGESWITH ATRAUMATIC FEATURES;

U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR STAPLINGSYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT;

U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR STAPLINGSYSTEM COMPRISING ROTARY FIRING SYSTEM; and

U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR STAPLINGSYSTEM COMPRISING LOAD CONTROL.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respectiveentireties:

U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS FORCOMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 14/984,552, entitled SURGICALINSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/019,220, entitled SURGICALINSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END EFFECTOR;

U.S. patent application Ser. No. 15/019,228, entitled SURGICALINSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,196, entitled SURGICALINSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY CONSTRAINT;

U.S. patent application Ser. No. 15/019,206, entitled SURGICALINSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE RELATIVETO AN ELONGATE SHAFT ASSEMBLY;

U.S. patent application Ser. No. 15/019,215, entitled SURGICALINSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,227, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK ARRANGEMENTS;

U.S. patent application Ser. No. 15/019,235, entitled SURGICALINSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN ARTICULATIONSYSTEMS;

U.S. patent application Ser. No. 15/019,230, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM ARRANGEMENTS; and

U.S. patent application Ser. No. 15/019,245, entitled SURGICALINSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respectiveentireties:

U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS FORCOMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/742,925, entitled SURGICAL ENDEFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS;

U.S. patent application Ser. No. 14/742,941, entitled SURGICAL ENDEFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES;

U.S. patent application Ser. No. 14/742,914, entitled MOVABLE FIRINGBEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS;

U.S. patent application Ser. No. 14/742,900, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM STRUCTURES WITH CENTERFIRING SUPPORT MEMBER FOR ARTICULATION SUPPORT;

U.S. patent application Ser. No. 14/742,885, entitled DUAL ARTICULATIONDRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS; and

U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULLARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/640,746, entitled POWERED SURGICALINSTRUMENT, now U.S. Patent Application Publication No. 2016/0256184;

U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE LEVELTHRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL INSTRUMENTS, now U.S.Patent Application Publication No. 2016/02561185;

U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE TISSUECOMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR MULTIPLE TISSUETYPES, now U.S. Patent Application Publication No. 2016/0256154;

U.S. patent application Ser. No. 14/640,935, entitled OVERLAID MULTISENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE TISSUECOMPRESSION, now U.S. Patent Application Publication No. 2016/0256071;

U.S. patent application Ser. No. 14/640,831, entitled MONITORING SPEEDCONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED SURGICALINSTRUMENTS, now U.S. Patent Application Publication No. 2016/0256153;

U.S. patent application Ser. No. 14/640,859, entitled TIME DEPENDENTEVALUATION OF SENSOR DATA TO DETERMINE STABILITY, CREEP, ANDVISCOELASTIC ELEMENTS OF MEASURES, now U.S. Patent ApplicationPublication No. 2016/0256187;

U.S. patent application Ser. No. 14/640,817, entitled INTERACTIVEFEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2016/0256186;

U.S. patent application Ser. No. 14/640,844, entitled CONTROL TECHNIQUESAND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH SELECT CONTROLPROCESSING FROM HANDLE, now U.S. Patent Application Publication No.2016/0256155;

U.S. patent application Ser. No. 14/640,837, entitled SMART SENSORS WITHLOCAL SIGNAL PROCESSING, now U.S. Patent Application Publication No.2016/0256163;

U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FORDETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A SURGICALSTAPLER, now U.S. Patent Application Publication No. 2016/0256160;

U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND POWERCOMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT, now U.S. PatentApplication Publication No. 2016/0256162; and

U.S. patent application Ser. No. 14/640,780, entitled SURGICALINSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING, now U.S. PatentApplication Publication No. 2016/0256161.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/633,576, entitled SURGICALINSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION, now U.S. PatentApplication Publication No. 2016/0249919;

U.S. patent application Ser. No. 14/633,546, entitled SURGICAL APPARATUSCONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER OF THE SURGICALAPPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE BAND, now U.S. PatentApplication Publication No. 2016/0249915;

U.S. patent application Ser. No. 14/633,560, entitled SURGICAL CHARGINGSYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE BATTERIES, now U.S.Patent Application Publication No. 2016/0249910;

U.S. patent application Ser. No. 14/633,566, entitled CHARGING SYSTEMTHAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A BATTERY, now U.S.Patent Application Publication No. 2016/0249918;

U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FORMONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED, now U.S.Patent Application Publication No. 2016/0249916;

U.S. patent application Ser. No. 14/633,542, entitled REINFORCED BATTERYFOR A SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2016/0249908;

U.S. patent application Ser. No. 14/633,548, entitled POWER ADAPTER FORA SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2016/0249909;

U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE SURGICALINSTRUMENT HANDLE, now U.S. Patent Application Publication No.2016/0249945;

U.S. patent application Ser. No. 14/633,541, entitled MODULAR STAPLINGASSEMBLY, now U.S. Patent Application Publication No. 2016/0249927; and

U.S. patent application Ser. No. 14/633,562, entitled SURGICAL APPARATUSCONFIGURED TO TRACK AN END-OF-LIFE PARAMETER, now U.S. PatentApplication Publication No. 2016/0249917.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/574,478, entitled SURGICALINSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND MEANSFOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER, now U.S. PatentApplication Publication No. 2016/0174977;

U.S. patent application Ser. No. 14/574,483, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS, now U.S. PatentApplication Publication No. 2016/0174969;

U.S. patent application Ser. No. 14/575,139, entitled DRIVE ARRANGEMENTSFOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2016/0174978;

U.S. patent application Ser. No. 14/575,148, entitled LOCKINGARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE SURGICALEND EFFECTORS, now U.S. Patent Application Publication No. 2016/0174976;

U.S. patent application Ser. No. 14/575,130, entitled SURGICALINSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A DISCRETENON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now U.S. PatentApplication Publication No. 2016/0174972;

U.S. patent application Ser. No. 14/575,143, entitled SURGICALINSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS, now U.S. PatentApplication Publication No. 2016/0174983;

U.S. patent application Ser. No. 14/575,117, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING BEAMSUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.2016/0174975;

U.S. patent application Ser. No. 14/575,154, entitled SURGICALINSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING BEAMSUPPORT ARRANGEMENTS, now U.S. Patent Application Publication No.2016/0174973;

U.S. patent application Ser. No. 14/574,493, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM, now U.S.Patent Application Publication No. 2016/0174970; and

U.S. patent application Ser. No. 14/574,500, entitled SURGICALINSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM, now U.S.Patent Application Publication No. 2016/0174971.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION,now U.S. Patent Application Publication No. 2014/0246471;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0246472;

U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2014/0249557;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now U.S. Pat. No.9,358,003;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0246478;

U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,326,767;

U.S. patent application Ser. No. 13/782,481, entitled SENSORSTRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S. Pat.No. 9,468,438;

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODSFOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS, now U.S.Patent Application Publication No. 2014/0246475;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Pat. No.9,398,911; and

U.S. patent application Ser. No. 13/782,536, entitled SURGICALINSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. PatentApplication Publication No. 2014/0263542;

U.S. patent application Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S. Pat.No. 9,332,987;

U.S. patent application Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT, now U.S. PatentApplication Publication No. 2014/0263564;

U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541;

U.S. patent application Ser. No. 13/803,210, entitled SENSORARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS,now U.S. Patent Application Publication No. 2014/0263538;

U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent Application PublicationNo. 2014/0263554;

U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. PatentApplication Publication No. 2014/0263565;

U.S. patent application Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,726;

U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAINCONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,727; and

U.S. patent application Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

U.S. patent application Ser. No. 14/200,111, entitled CONTROL SYSTEMSFOR SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No.2014/0263539.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled STERILIZATIONVERIFICATION CIRCUIT, now U.S. Patent Application Publication No.2015/0272581;

U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION OFNUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now U.S. Patent ApplicationPublication No. 2015/0272580;

U.S. patent application Ser. No. 14/226,117, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL, now U.S.Patent Application Publication No. 2015/0272574;

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now U.S. PatentApplication Publication No. 2015/0272579;

U.S. patent application Ser. No. 14/226,093, entitled FEEDBACKALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.Patent Application Publication No. 2015/0272569;

U.S. patent application Ser. No. 14/226,116, entitled SURGICALINSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent ApplicationPublication No. 2015/0272571;

U.S. patent application Ser. No. 14/226,071, entitled SURGICALINSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S. PatentApplication Publication No. 2015/0272578;

U.S. patent application Ser. No. 14/226,097, entitled SURGICALINSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent ApplicationPublication No. 2015/0272570;

U.S. patent application Ser. No. 14/226,126, entitled INTERFACE SYSTEMSFOR USE WITH SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272572;

U.S. patent application Ser. No. 14/226,133, entitled MODULAR SURGICALINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272557;

U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent ApplicationPublication No. 2015/0277471;

U.S. patent application Ser. No. 14/226,076, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION, now U.S.Patent Application Publication No. 2015/0280424;

U.S. patent application Ser. No. 14/226,111, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272583; and

U.S. patent application Ser. No. 14/226,125, entitled SURGICALINSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Patent ApplicationPublication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY ANDSENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent ApplicationPublication No. 2016/0066912;

U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT WITHINTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S. PatentApplication Publication No. 2016/0066914;

U.S. patent application Ser. No. 14/478,908, entitled MONITORING DEVICEDEGRADATION BASED ON COMPONENT EVALUATION, now U.S. Patent ApplicationPublication No. 2016/0066910;

U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE SENSORSWITH ONE SENSOR AFFECTING A SECOND SENSOR'S OUTPUT OR INTERPRETATION,now U.S. Patent Application Publication No. 2016/0066909;

U.S. patent application Ser. No. 14/479,110, entitled POLARITY OF HALLMAGNET TO DETECT MISLOADED CARTRIDGE, now U.S. Patent ApplicationPublication No. 2016/0066915;

U.S. patent application Ser. No. 14/479,098, entitled SMART CARTRIDGEWAKE UP OPERATION AND DATA RETENTION, now U.S. Patent ApplicationPublication No. 2016/0066911;

U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE MOTORCONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent ApplicationPublication No. 2016/0066916; and

U.S. patent application Ser. No. 14/479,108, entitled LOCAL DISPLAY OFTISSUE PARAMETER STABILIZATION, now U.S. Patent Application PublicationNo. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/248,590, entitled MOTOR DRIVENSURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now U.S. PatentApplication Publication No. 2014/0305987;

U.S. patent application Ser. No. 14/248,581, entitled SURGICALINSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE OPERATED FROMTHE SAME ROTATABLE OUTPUT, now U.S. Patent Application Publication No.2014/0305989;

U.S. patent application Ser. No. 14/248,595, entitled SURGICALINSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE OPERATION OF THESURGICAL INSTRUMENT, now U.S. Patent Application Publication No.2014/0305988;

U.S. patent application Ser. No. 14/248,588, entitled POWERED LINEARSURGICAL STAPLER, now U.S. Patent Application Publication No.2014/0309666;

U.S. patent application Ser. No. 14/248,591, entitled TRANSMISSIONARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. Patent ApplicationPublication No. 2014/0305991;

U.S. patent application Ser. No. 14/248,584, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR ALIGNING ROTARYDRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS, now U.S. PatentApplication Publication No. 2014/0305994;

U.S. patent application Ser. No. 14/248,587, entitled POWERED SURGICALSTAPLER, now U.S. Patent Application Publication No. 2014/0309665;

U.S. patent application Ser. No. 14/248,586, entitled DRIVE SYSTEMDECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S. PatentApplication Publication No. 2014/0305990; and

U.S. patent application Ser. No. 14/248,607, entitled MODULAR MOTORDRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION ARRANGEMENTS, nowU.S. Patent Application Publication No. 2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. Provisional Patent Application Ser. No. 61/812,365, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR;

U.S. Provisional Patent Application Ser. No. 61/812,376, entitled LINEARCUTTER WITH POWER;

U.S. Provisional Patent Application Ser. No. 61/812,382, entitled LINEARCUTTER WITH MOTOR AND PISTOL GRIP;

U.S. Provisional Patent Application Ser. No. 61/812,385, entitledSURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION MOTORS AND MOTORCONTROL; and

U.S. Provisional Patent Application Ser. No. 61/812,372, entitledSURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

Various staples disclosed herein comprise a flat-formed staple which canbe cut and/or stamped from a sheet of material, for example. The sheetof material can be metallic and can comprise stainless steel and/ortitanium, for example. In at least one instance, outlines can be traced,etched, and/or cut into the sheet of material which are machined and/orlaser cut to form the staples into a manufactured shape.

The staples comprise a pair of staple legs and a staple base portion, orcrown, from which the staple legs extend. Each staple leg comprises astaple tip, or piercing portion, which is configured to pierce thetissue and contact a corresponding forming pocket of the anvil of thesurgical stapling instrument. The staple legs are configured to changeshape to achieve a formed configuration to fasten the tissue. The staplebase portion defines a first plane and the staple legs define a secondplane which is laterally offset from but at least substantially parallelto the first plane. Embodiments are envisioned where the first andsecond planes are not parallel.

The flat-formed staple 100 depicted in FIGS. 1-4 comprises a proximalstaple leg 110, a distal staple leg 120, and a staple base portion 130.The staple 100 further comprises vertical transition portions, or bends,118, 128 and lateral transition portions, or bends, 116, 126. Thevertical transition portions 118, 128 bend, or extend, the legs 110, 120vertically, or upward, from the staple base portion 130. The lateraltransition portions 116, 126 extend the staple legs 110, 120 laterallyoutward, or at least substantially perpendicularly with respect to thestaple base portion 130. The staple legs 110, 120 define a first planeand the staple base portion 130 defines a second plane. Together, thevertical transition portions 118, 128 and the lateral transitionportions 116, 126 permit the staple legs 110, 120 to be laterally offsetand parallel with respect to the staple base portion 130.Stated anotherway, the first plane is offset from and at least substantially parallelto the second plane. In FIGS. 1-4, the first plane is offset in thenegative Y direction. Other staples may be used in conjunction with aplurality of staples 100 where the other staples comprise a first planewhich is offset in the positive Y direction. The use of both types ofstaples permits staple rows to be nested, or interwoven, where staplelegs of neighboring rows may be at least substantially aligned and/orshare a common longitudinal axis. In various instances, the staple rowscan be nested to provide denser staple rows.

The proximal staple leg 110 and the distal staple leg 120 comprisestaple tips 112, 122 and corners 114, 124, respectively. The tips 112,122 are configured to pierce tissue and contact a forming pocket of ananvil of a surgical stapling instrument. The tips 112, 122 contact theanvil when the staple 100 receives a driving force to eject the staple100 from a corresponding staple cavity in the staple cartridge. The tips112, 122 and/or legs 110, 120 of the staple 100 will then begin formingfrom an unfired configuration to a fired configuration. The proximalstaple leg 120 further comprises a leading engagement foot 117comprising a chamfered surface, or edge, 119. As the sled contacts thestaple 100 upon the sled's distal translation, a feature of the sled canengage the leading engagement foot 117 to aid in preventing longitudinalstaple roll, or rotation, for example. The engagement foot 117 cancomprise a push point that is configured to be pushed on to load thestaple 100 into a staple cartridge.

Since the staple 100 is a flat-formed staple, the staple legs 110, 120,tips 112, 122, and/or other portions of the staple 100 can be furtherdeveloped, or worked, after being stamped from a flat, or at leastsubstantially flat, stock. Further developing the staple 100 can providespecific properties creating and/or altering preferential bendingplanes, toughness, and/or elasticity, for example. Traditionalwire-formed staples comprise desirable properties advantageous forsurgical fastening and can be implemented with the staple 100. Methodsfor constructing the corners 114, 124 and/or tips 112, 122, for example,may include any suitable process including cold working, for example. Aspecific process may include coining by working the corners 114, 124into a rounded, angled, oblique, and/or parabolic profile, for example.The staple tips 112, 122 can also be worked using similar methods toprovide an adequate tip configured to pierce tissue and form against acorresponding forming pocket of the anvil.

The staple base portion 130 comprises an inclined drive surface 132, afinal drive surface 131, and a distal wall 133. In various instances,the staple 100 is supported in a staple cartridge by a pan where thefinal drive surface 131 is configured to rest on the pan. In variousother instances where a staple cartridge is pan-less, the final drivesurface does not rest on a pan; rather, the final drive surfacecomprises an initial position residing above a bottom surface of thepan-less staple cartridge. This would allow a bottom surface of the sledand the bottom surface of the pan-less staple cartridge to be at leastsubstantially flush as the sled translates through the cartridge. Thedrive surface 132 of each staple base portion 130 is configured toreceive the driving force F_(S) from the sled of the surgical staplinginstrument. When the sled translates distally through the staplecartridge, the sled contacts the drive surface 132 to lift the staple100 out of the cartridge and, in addition, contact the final drivesurface 131 to form the staple 100 into its fired configuration.

The distal wall 133 acts as a distal-most wall of the staple baseportion 130 and is positioned proximal of the distal staple leg 120resulting in a lack of any portion of the staple base portion 130underneath the distal staple leg 120.Having a greater amount of mass inthe base portion 130 of the staple 100 increases the ability of thestaple 100 to resist rotational motion caused by the moment M_(S)applied by the sled. Increasing the moment of inertia of the staple baseportion 130 increases the ability to resist rotational motion. As aresult, a greater torque, or larger moment, would be required to causelongitudinal staple roll.

The staple base portion 130 further comprises a top surface, orcompression surface, 136 comprising a proximal surface 139, anintermediate surface 138, and a distal surface 137. The proximal surface139 is angled, or slanted, upward toward the proximal leg 110. Thedistal surface 137 is angled, or slanted, upward toward the distal leg120. The intermediate surface 138 is at least substantially parallel tothe final drive surface 131. This valley-like configuration limits thestress concentration of tissue captured near the transition portions118, 128, 116, 126 where the legs 110, 120 extend from the staple baseportion 130. In various instances, these surfaces 137, 138, 139 can becurved to create a concave surface. In traditional staples, when formed,the connections where the legs meet the staple base produce locationsresponsible for highly localized tissue stress. This is especially truein the event that such a traditional staple buckles, or is crushed, orflattened, rather than formed into a true “B” configuration. In variousinstances, the dynamics of the staple 100 are predictable when ejectedfrom a staple cartridge. As the staple 100 is ejected from itscorresponding staple cavity, a driving force F_(s) from the sledgenerates a moment M_(S). One preventive measure for preventing stapleroll includes increasing the moment of inertia of the staple 100,discussed above, which is configured to prevent, as illustrated in FIG.2, longitudinal roll, or rotation of the staple. In the event that thestaple 100 rolls longitudinally in the distal direction, or, in otherwords, rotates counterclockwise about the Y axis, outer, longitudinalstaple leg surfaces 115, 125 of the staple 100 will contact the guidesurfaces, or sidewalls, of the staple cartridge. This contact producescorresponding reaction forces F_(C1) and F_(C2).More particularly, asthe staple 100 is driven out of the staple cavity and rotated about theY axis, the wall 115 of the proximal staple leg 110 contacts a proximalsidewall of the staple cartridge producing a reaction force F_(C2) whichacts upon the staple leg 110 below the center of mass. The wall 125 ofthe distal staple leg 120 contacts a distal sidewall of the staplecartridge producing a reaction force F_(C1) which acts upon the stapleleg 120 above the center of mass. Both reaction forces, F_(C1) andF_(C2), contribute to a reactional moment M_(RC) to counteract, orbalance, the applied moment M_(S) acting on the staple 100.The reactionforces discussed herein may be distributed loads acting upon a surfacearea of each of the staple legs 110, 120. In certain instances, thereaction force F_(C2) can be about 0.

The moment of inertia of the staple 100 is also configured to prevent,as illustrated in FIG. 4, lateral roll, or rotation of the staple 100.The staple base portion 130 comprises a notch 134 defined in the topsurface 136 on a side of the staple base portion 130 closest to the legs110, 120.The notch 134 contributes to the predictability of the dynamicsof the staple 100 before formation and upon formation when ejected fromthe staple cartridge. For example, referring primarily to FIG. 4, thenotch 134 is configured to induce rotation of the staple 100 toward aparticular cavity sidewall. In the event that the staple 100 rollslaterally, or, in other words, rotates in the direction of the appliedmoment M_(S), outer, lateral staple leg walls 111, 121 of the staple 100will contact the guide surfaces, or sidewalls, of the staple cartridgeproducing corresponding reaction forces F_(C1) and F_(C2). For example,as the staple 100 is driven out of the staple cavity and rotated in thedirection of the applied moment M_(S), the walls 111, 121 of the staplelegs 110, 120 contact a corresponding sidewall of the staple cartridgeproducing a reaction force F_(C1) which act upon the staple legs 110,120 above the center of mass. An outer lateral wall 135 of the staplebase portion 130 contacts another corresponding sidewall of the staplecartridge producing a reaction force F_(C2) which acts upon the staplebase portion 130 below the center of mass. Reaction forces F_(C1) andF_(C2) produce a reactional moment M_(RC) to counteract, or balance, theapplied moment M_(S) acting on the staple 100 from the sled. Thereaction forces discussed herein may be distributed loads acting upon asurface area of each of the staple legs 110, 120 and the staple baseportion 130.In various instances, the staple 100 is encouraged to rolllaterally in the direction of the applied moment M_(S) to control whichwalls of the staple cavity are going to be contacted for staple guidanceas the staple 100 is ejected from the staple's 100 corresponding staplecavity.

A staple cartridge assembly 240 is illustrated in FIGS. 5-6. The staplecartridge assembly 240 comprises a cartridge body 242.The cartridge body242 is positionable in and removable from a jaw of a surgical staplinginstrument. As a result, the staple cartridge 240 is replaceable;however, other instances are envisioned in which the staple cartridge240 is not replaceable. The cartridge body 242 comprises a proximal end246, a distal end 247, and a deck 245 extending between the proximal end246 and the distal end 247. The deck 245 is configured to support thetissue of a patient when the tissue is compressed against the deck 245.

The cartridge body 242 further comprises a plurality of staple cavities244 defined therein. The staple cavities 244 are arranged in sixlongitudinal rows extending between the proximal end 246 and the distalend 247; however, any suitable arrangement of staple cavities 244 can beutilized. A staple, such as staple 100 (FIG. 1), for example, can beremovably stored in each staple cavity 244. As discussed in greaterdetail below, the staples are ejected from the staple cavities 244 by afiring member when the firing member is moved from the proximal end 246of the cartridge body 242 toward the distal end 247.

Further to the above, the staples are moved from an unfired position toa fired position by the firing member. The firing member lifts thestaples toward an anvil, such as anvil 250 (FIG. 7), for example, todeform the staples between an unfired, undeformed configuration and afired, deformed configuration. The cartridge body 242 further comprisesa elongate slot 243 defined therein. The elongate slot 243 is configuredto receive the staple firing member and/or a tissue cutting membertherein when the staples are ejected from the staple cavities 244.

As illustrated in FIGS. 5-6, the cartridge body 2010 comprises steps245′ and 245″ which extend upwardly from the deck 245. Morespecifically, the steps 245′ extend upwardly from the deck 245 and thesteps 245″ extend upwardly from the steps 245′. As a result, threediscrete deck surfaces 245 a, 245 b, 245 c are defined in the deck 245,wherein the deck surface 245 a may apply a larger compressive pressureto the tissue than the deck surface 245 b, and wherein the deck surface245 b may apply a larger compressive pressure to the tissue than thedeck surface 245 c. As illustrated in FIGS. 5-6, the deck surface 245 cis shorter than the deck surfaces 245 a and 245 b. In addition, the decksurface 245 b is shorter than the deck surface 245 a. Said another way,the deck surfaces 245 a, 245 b, 245 c comprise first, second, and thirdheights, respectively, relative to a plane define by a bottom surface248 (FIG. 7) of the staple cartridge 240, wherein the first height isgreater than the second height, and wherein the second height is greaterthan the third height. Furthermore, the deck surfaces 245 a, 245 b, 245c are laterally offset from one another relative to the elongate slot243. The deck surface 245 a is positioned closer to the elongate slot243 than the deck surface 245 b. In addition, the deck surface 245 b ispositioned closer to the elongate slot 243 than the deck surface 245 c.That said, any suitable arrangement of the deck surfaces 245 a, 245 b,245 c can be utilized.

Further to the above, as illustrated in FIGS. 5-6, the staple cavities244 comprise an inner row of staple cavities 244 a defined in the decksurface 245 a, an intermediate row of staple cavities 244 b defined inthe deck surface 245 b, and an outer row of staple cavities 244 cdefined in the deck surface 245 c. As a result, the inner row of staplecavities 244 a is positioned closer to the elongate slot 243 than theintermediate row of staple cavities 244 b, and the intermediate row ofstaple cavities 244 b is positioned closer to the elongate slot 243 thanthe outer row of staple cavities 244 c.

The staple cavities 244 c are similar to the staple cavities 244 a, 244b in many respects. For instance, the staple cavities, 244 a, 244 b, 244c each comprise a central slot 249 having a proximal end and a distalend, a proximal staple leg guide 249′ extending laterally from theproximal end of the central slot 249, and a distal staple leg guide 249″extending laterally from the distal end of the central slot 249.Thatsaid, the staple cavities 244 b and the staple cavities 244 c areoriented in different directions. More particularly, the staple legguides 249′, 249″ of the staple cavities 244 b extend toward the staplecavities 244 a, while the staple leg guides 249′, 249″ of the staplecavities 100 c extend away from the staple cavities 100 a; however, anysuitable arrangement can be utilized.

The various instances of the staple cartridge assemblies disclosedherein can have any suitable number of staples and/or any suitable sizeof staples. In certain instances, all of the staples stored in thestaple cartridge assembly 240 (FIG. 5) have the same, or at leastsubstantially the same, size. Referring to FIG. 1, each staple 100comprises an unformed, or unfired, overall height H1 defined between thebottom of the base 130 and the tips of the staple legs 112, 122.Similarly, each staple 100 comprises a tissue capture area definedbetween the top of the base 130 and the tips of the staple legs 112, 122which have the same height H2 when the staple 100 is in its unformedheight.

In contrast to the above, a first group of staples stored in the staplecartridge 240 can have a first unformed height H1 and a second group ofstaples can have a second unformed height H2 which is different than thefirst unformed height H1. Also in contrast to the above, a first groupof staples stored in the staple cartridge 240 can have a first tissuecapture height H1 and a second group of staples can have a second tissuecapture height H2 which is different than the first tissue captureheight H2.

Referring to FIGS. 7-11, the staples 100 comprise a first row of staples100 a removably stored in the inner row of staple cavities 244 a, asecond row of staples 100 b removably stored in the intermediate row ofstaple cavities 244 b, and a third row of staples 100 c removably storedin the outer row of staple cavities 244 c. The rows of staples 100 a,100 b, 100 c comprise different unformed heights; however, in otherarrangements, the rows of staples 100 a, 100 b, 100 c may comprise thesame unformed height H1. Also, the rows of staples 100 a, 100 b, 100 ccomprise different tissue capturing heights; however, in otherarrangements, the rows of staples 100 a, 100 b, 100 c may comprise thesame tissue capturing height H2.

As illustrated in FIG. 9, the staples 100 c comprise an unformed height103 which is greater than an unformed height 102 of the staple 100 b.Also, the unformed height 102 of the staples 100 b is greater than anunformed height 101 of the staples 100 a. In addition, the staples 100 ccomprise a tissue capturing height 106 which is greater than a tissuecapturing height 105 of the staple 100 b in an unformed configuration.Also, the tissue capturing height 105 of the staples 100 b is greaterthan a tissue capturing height 104 of the staples 100 a in the unformedconfiguration. As a result, the staples 100 c comprise a tissuecapturing area which is greater than a tissue capturing area of thestaple 100 b in an unformed configuration. In addition, the tissuecapturing area of the staples 100 b is greater than the tissue capturingarea of the staples 100 a in the unformed configuration.

The staples 100 are driven between unfired positions and fired positionsby a firing member, such as sled 290 (FIG. 8), for example. The sled 290comprises ramps or wedges 291 a, 291 b, 291 c which are configured todirectly engage the staples 100 a, 100 b, 100 c, respectively, and liftthe staples 100 a, 100 b, 100 c toward an anvil, such as anvil 250, forexample, as illustrated in FIG. 7. The sled 290 utilizes a wedge foreach longitudinal row of staples 100 a, 100 b, 100 c; however, the sled290 may have any suitable number of wedges. Each of the wedges 291 a,291 b, 291 c comprises an angled drive surface which slides under thestaples 100 a, 100 b, 100 c as the sled 290 is advanced from theproximal end 246 of the staple cartridge 240 toward the distal end 247of the staple cartridge 240.The base 130 of each staple 100 a, 100 b,100 c comprises an angled drive surface 132 which is directly contactedby the drive surface of the wedges 291 a, 291 b, 291 c. Stated anotherway, each staple 100 a, 100 b, 100 c comprises its own integrally-formeddriver having a drive surface 132.The staples 100 a, 100 b, 100 c arecomprised of metal and, as a result, the integrally-formed driver isalso comprised of metal. That said, the staples disclosed herein can becomprised of any suitable material.

Further to the above, the drive surfaces of the wedges 291 a, 291 b, 291c comprise apex portions defining peak drive surfaces 292 a, 292 b, 292c. As illustrated in FIG. 8, the wedges 291 a, 291 b, 291 c comprisedifferent heights. The wedge 291 c is shorter than the wedge 291 b, andthe wedge 291 b is shorter than the wedge 291 a. The wedge 291 acomprises a first height 294 defined between a bottom surface 293 of thesled 290 and the peak drive surface 292 a. Likewise, the wedge 291 bcomprises a second height 295 defined between the bottom surface 293 ofthe sled 290 and the peak drive surface 292 b. Also, the wedge 291 ccomprises a third height 296 defined between the bottom surface 293 ofthe sled 290 and the peak drive surface 292 c. As illustrated in FIG. 8,the heights 294, 295, 296 are different. The first height 294 is shorterthan the second height 295, and the second height 295 is shorter thanthe third height 296. In other instances, however, the heights 294, 295,296 can be the same, or at least substantially the same, size.

Referring to FIG. 7, an end effector 220 is depicted in a closedconfiguration. A forming gap is defined between the cartridge deck 245and the anvil 250. A first gap height (A) is defined between the decksurface 245 a and anvil pockets 254 a which are configured to deform thestaples 100 a. A second gap height (B) is defined between the decksurface 245 b and anvil pockets 254 b which are configured to deform thestaples 100 b. A third gap height (C) is defined between the decksurface 245 c and anvil pockets 254 c which are configured to deform thestaples 100 c. The gap height (A) is shorter than the gap height (B),and the gap height (B) is shorter than the gap height (C). Thisarrangement improves fluid flow through tissue captured by the endeffector 220 in a direction away from the elongate slot 243 by creatinga pressure gradient where more pressure is applied to the tissue closerto the cut-line or the elongate slot 243. In other instances, however,the forming gap may comprise a constant, or at least substantiallyconstant, height between the cartridge deck 245 and the anvil 250.

Referring to FIGS. 7-11, the sled 290 and the anvil 250 cooperate toform the staples 100 a, 100 b, 100 c to different formed heights 107,108, 109, respectively. As illustrated in FIG. 10, the staples 100 a,100 b, 100 c can be proportionally formed by the sled 290 and the anvil250. As illustrated in FIG. 10, the staples 100 a, 100 b, 100 c comprisedifferent unformed heights, and are fully or completely formed to astandard “B” shaped formation. The difference in unformed height betweenthe staples 100 a, 100 b, 100 c causes the staples 100 a, 100 b, 100 cto comprise different tissue capturing areas in the formed configurationeven though the staples 100 a, 100 b, 100 c are proportionally formed.

As illustrated in FIG. 10, a formed staple 100 a comprises a smallertissue capturing area than a formed staple 100 b, and a formed staple100 b comprises a smaller tissue capturing area than a formed staple 100c. In such instances, the formed staple 100 a exerts more pressure ontissue captured by the formed staple 100 a than the pressure exerted bythe formed staple 100 b on tissue captured by the formed staple 100 b.In addition, the pressure exerted by the formed staple 100 b on thetissue captured by the formed staple 100 b is greater than the pressureexerted by the staple 100 c on tissue captured by the formed staple 100c.

In certain instances, a first group of staples, a second group ofstaples, and/or a third group of staples may comprise the same unformedheight but are deformed to different deformed heights by utilizing asled that comprises wedges with different heights such as, for example,the sled 290. The sled 290 may cause the first group of staples to befully formed, the second group of staples to be partially formed, andthe third group of staples to be partially formed to a lesser degreethan the second group of staples. This is the result of the wedges 291a, 291 b, 291 c of the sled 290 having different heights 294, 295, 296,respectively. In such instances, the first group of staples can apply alarger pressure to the tissue than the second group of staples and,similarly, the second group of staples can apply a larger pressure tothe tissue than the third group of staples.

Referring to FIG. 11, the staples 100 d, 100 e, 100 f comprise the sameunformed height. Yet the staples 100 d, 100 e, 100 f can be formed todifferent formed heights by causing the staples 100 d, 100 e, 100 f toformed to different degrees. For example, the staples 100 d are moretightly formed than the staples 100 e, and the staples 100 e are moretightly formed than the staples 100 f. In result, the formed staples 100d comprise a smaller tissue capturing area than the formed staples 100e, and the formed staples 100 e comprise a smaller tissue capturing areathan a formed staple 100 f. In such instances, the formed staple 100 dexerts more pressure on tissue captured by the formed staple 100 d thanthe pressure exerted by the formed staple 100 e on tissue captured bythe formed staple 100 e. In addition, the pressure exerted by the formedstaple 100 e on the tissue captured by the formed staple 100 e isgreater than the pressure exerted by the staple 100 f on tissue capturedby the formed staple 100 f.

In various instances, the height of the base 130 (FIG. 1) can be variedsuch that a first group of staples, a second group of staples, and/or athird group of staples may comprise different base heights. For example,the row of staples 100 a may comprise a first base height greater than acorresponding base height of the row of staples 100 b, and the row ofstaples 100 b may comprise a base height greater than a correspondingbase height of the row of staples 100 c.

Various other suitable staples, staple cartridge, and end effectors foruse with the present disclosure can be found in U.S. patent applicationSer. No. 14/836,036, entitled STAPLE CARTRIDGE ASSEMBLY WITHOUT A BOTTOMCOVER, and filed Aug. 26, 2015, which is hereby incorporated byreference herein in its entirety.

Referring now to FIGS. 12-17, various staple cartridges 340 (FIG. 12),340′ (FIG. 14), 340″ (FIG. 15) are depicted. The staple cartridges 340,340′, 340″ are similar in many respects to the staple cartridge 240. Forexample, the staple cartridges 340, 340′, 340″ comprise a cartridge body342, staple cavities 344, a cartridge deck 345, a proximal portion 346,a distal portion 347, and an elongate slot 343 extending longitudinallyfrom the proximal portion 346 to the distal portion 347. The cartridgedeck 345 includes steps 345′, 345″ that define stepped deck surfaces 345a, 345 b, 345 c, which comprise rows of staple cavities 344 a, 344 b,344 c, respectively.

Referring to FIGS. 12-14, the staple cartridges 340, 340′ are providedwith stepped deck surfaces that are equipped tissue retention featuresor cleats 348. The stepped deck surfaces provide several advantages suchas facilitating fluid outflow during a tissue stapling procedure;however, the stepped nature of the deck surfaces reduces tractionagainst the tissue gripped between a staple cartridge and an anvil. Toresist tissue slippage, stepped deck surfaces of staple cartridges 340(FIG. 12), 340′ (FIG. 14) are equipped with tissue retention features orcleats 348 that are strategically placed in various arrangements thatimprove traction against the tissue without significantly interferingwith or reducing the functionality of the stepped deck surfaces.

As illustrated in FIG. 12, the cartridge deck 345 includespyramid-shaped cleats 348. The pyramid-shaped cleats 348 may includesquare and/or triangular bases and sloping sides that may extendgenerally away from cartridge deck 345. As illustrated in FIG. 12, thecleats 348 generally comprise a base 351 defined in the cartridge deck345, and a peak 341 narrower than the base 351. In certain instances,the cartridge deck 345 may include pillar-shaped cleats which mayinclude square and/or rectangle bases and substantially perpendicularsides extending generally away from the deck surfaces 345 a, 345 b, 345c. In certain instances, the cartridge deck 345 may include cone-shapedcleats and/or dome-shaped cleats 1042. Cleats with other suitable shapesand sizes can also be utilized.

The cleats 348 can be made, or at least partially made, from the samematerial or materials as the cartridge deck 345. Alternatively, thecleats 348 may comprise a different material composition than thecartridge deck 345. In various instances, the cleats 348 can be madefrom a plastic or a ceramic material. In certain instances, the cleats348 may comprise one or more biocompatible elastomeric polymers. Incertain instances, the cleats are made, or at least partially made, froma medical grade plastic material such as, for example, a glass filledpoly-carbonate material. In certain instances, the cleats 348 are made,or at least partially made, from one or more resilient materials. Incertain instances, the cleats 348 are more flexible than the cartridgedeck 345 to ensure an atraumatic interaction with the tissue.

Cleats 348 can be spatially arranged onto the cartridge deck 345 in apredetermined pattern or array. For example, cleats 348 can be spatiallyarranged onto the cartridge deck 345 in multiple rows which may extendlongitudinally along a length of the cartridge deck 345, which can be inparallel with one another.

As illustrated in FIG. 12, the cleats 348 are spatially arranged in acleat pattern 350 configured to define a perimeter around the staplecavities 344. The cleats 348 of the cleat pattern 350 are positionedoutside the area of the cartridge deck 345 occupied by the staplecavities 344. The cleats 348 on one side of a plane defined by theelongate slot 343 are mirror images of corresponding cleats 348 on anopposite side of the plane. More of the cleats 348 of the cleat pattern350 are positioned on the external deck surfaces 345 c than the internaldeck surfaces 345 b, 345 a. This creates a barrier against tissueslippage while minimizing interference with the fluid outflowfunctionality of the stepped cartridge deck 345. In the same vein, thecleats 348 that are positioned on the deck surfaces 345 c are limited toexternal area of the deck surfaces 345 c, as illustrated in FIG. 12.

Further to the above, as illustrated in FIG. 13, the cleat pattern 350is more tightly formed at the distal portion 347 and/or the proximalportion 346 than an intermediate portion 349 that includes the staplecavities 344. The distance between adjacent cleats 348 of theintermediate portion 349 is greater than the distance between adjacentcleats 348 of the distal portion 347. Likewise, the distance betweenadjacent cleats 348 of the intermediate portion 349 is greater than thedistance between adjacent cleats 348 of the proximal portion 346.Furthermore, the cleats 348 in the deck surfaces 345 a, 345 b, arepositioned proximal and/or distal to the rows of staple cavities 344 a,344 b.This arrangement of the cleat pattern 350 is designed to improvetissue traction without significantly interfering with or reducing thefunctionality of the stepped deck surfaces, as described above.

Referring to FIG. 14, a cleat pattern 360 is utilized with the staplecartridge 340′. The cleats 348 of the cleat pattern 360 are limited tothe proximal portion 346 and distal portion 347 of the staple cartridge340 that are void of the staple cavities 344. In other words, the cleats348 of the cleat pattern 360 are positioned outside the intermediateportion 349 that includes the staple cavities 344. The cleats 348 of thecleat pattern 360 are distributed on the cartridge deck 345 in areasthat are void of the staple cavities 344 which are proximal and distalto the intermediate portion 349.

Referring again to FIG. 14, the cleats 348 of the cleat pattern 360 arearranged in rows 348 a, 348 b, 348 c which extend or protrude from decksurfaces 345 a, 345 b, 345 c, respectively. The rows 348 a, 348 b, 348 care aligned with the rows of the staple cavities 344 a, 344 b, 344 c,respectively, to provide appropriate traction against tissue slippagethat is caused by the stepped nature of the stepped cartridge deck 345.The cleats of the cleat rows 348 a, 348 b, 348 c are spatially arrangedon the deck surfaces 345 a, 345 b, 345 c, respectively, at positionsthat are proximal and distal to the rows of staple cavities 344 a, 344b, 344 c, respectively. The number, size, and/or shape of the cleats ineach of the cleat rows 348 a, 348 b, 348 c can be adjusted to provide anappropriate amount of traction against the tissue slippage at each ofthe deck surfaces 345 a, 345 b, 345 c, for example.

In various instances, the cleats of the deck surfaces 345 a, 345 b, 345c include different cleat heights. For example, as illustrated in FIG.16, the cleats of the cleat row 348 a may comprise a first cleat heightH1 smaller than a second cleat height H2 of corresponding cleats of thecleat row 348 b, which is smaller than a third cleat height H3 ofcorresponding cleats of the cleat row 348 c. That said, cleats withother cleat height arrangements can be utilized.

Referring again to FIG. 16, the cleat heights of the cleat rows 348 a,348 b, 348 c can be selected to compensate for the difference in heightbetween the deck surfaces 345 a, 345 b, 345 c. As a result, the peaks341 of the cleat rows 348 a, 348 b, 348 c can define a plane extendingin parallel, or substantially in parallel, with the deck surfaces 345 a,345 b, 345 c. In other words, the combined height of the deck surfaces345 a, 345 b, 345 c and corresponding cleats from the cleat rows 348 a,348 b, 348 c, respectively, may amount to the same, or substantially thesame, height, for example. In certain instances, external cleats maycomprise greater heights than internal cleats to provide a greatertraction at peripheral portions of the cartridge deck 345. Asillustrated in FIG. 16, the tissue traction provided by cleats of thecleat row 348 c at the external deck surface 345 c is greater than thetissue traction provided by cleats of the cleat row 348 b at theintermediate deck surface 345 b, which is greater than the tissuetraction provided by cleats of the cleat row 348 a at the internal decksurface 345 a. As a result, the cleat pattern 350 creates atissue-traction gradient where tissue closer to the elongate slot 343experiences a greater traction than tissue further away from theelongate slot 343.

Referring again to FIG. 16, an end effector 220′ includes a staplecartridge 340′ and an anvil 250. The end effector 220′ is similar inmany respects to the end effector 220 (FIG. 7). The end effector 220′ isdepicted in a closed configuration. A forming gap is defined between thecartridge deck 345 and the anvil 250. The cleat rows 348 a, 348 b, 348 cprotrude from the deck surfaces 345 a, 345 b, 345 c, respectively,toward the forming gap between the cartridge deck 345 and the anvil 250.The cleat rows 348 a, 348 b, 348 c are configured to provide appropriatetraction for tissue captured between the anvil 250 and the cartridgedeck 340 to resist slippage of the captured tissue. In variousinstances, the peaks 341 of corresponding cleats of the cleat rows 348a, 348 b, 348 c are the same or, at least substantially the same,distance from a datum in the anvil 250. In various instances, one ormore of the cleats 348 can function as gap setting members configured toset a minimum forming gap between a cartridge deck of a staple cartridgeand anvil in a closed configuration.

FIGS. 15 and 17 illustrate a staple cartridge 340″ which is similar inmany respects to other staple cartridges described herein such as, forexample, the staple cartridge 340. The staple cartridge 340″ comprisesgap setting members 370 configured to set a minimum forming gap betweenthe staple cartridge 340″ and an anvil 250. In a fully closedconfiguration, the anvil 250 is configured to rest against the gapsetting members 370. A predetermined minimum gap is set between theanvil 250 and the cartridge deck 340″ by the transverse gap settingmembers 370 in the fully closed configuration.

The number, height, size, arrangement, and/or shape of the gap settingmembers 370 can be selected to set a suitable minimum gap between theanvil 250 and the cartridge deck 340. As illustrated in FIGS. 15 and 17,the gap setting members 370 comprise a proximal gap setting member 370 aextending transversely in a proximal portion 346 of the staple cartridge340″, an intermediate gap setting member 370 b extending transversely inan intermediate portion 349 of the staple cartridge 340″, and a distalgap setting member 370 c extending transversely in a distal portion 347of the staple cartridge 340″. As illustrated in FIG. 17, the gap settingmembers 370 a, 370 b, 370 c comprise different heights. In otherinstances, however, the gap setting members 370 a, 370 b, 370 c maycomprise the same, or substantially the same, height.

As illustrated in FIG. 17, the distal gap setting member 370 c isgreater in height than the intermediate gap setting member 370 b, whichis greater in height than the proximal gap setting member 370 a. As aresult, a minimum forming gap 372 that comprises a size gradient isformed between the cartridge deck 340 and the anvil 250 in the fullyclosed configuration. The minimum forming gap 372 comprises a firstvolume at the proximal portion 346 of the staple cartridge 340″, asecond volume at the intermediate portion 349 of the staple cartridge340″, and a third volume at the distal portion 347 of the staplecartridge 340″, wherein the first volume is greater than the secondvolume, and wherein the second volume is greater than the third volume.In certain instances, however, the distal gap setting member 370 c canbe smaller in height than the intermediate gap setting member 370 b,which can be smaller in height than the proximal gap setting member 370a. In such instances, the first volume can be smaller than the secondvolume, and the second volume can be smaller than the first volume.

The gap setting members 370 a, 370 b, 370 c are spaced apart. Asillustrated in FIG. 15, the gap setting member 370 a is positionedproximal to the staple cavities 344 and the gap setting member 370 c ispositioned distal to the staple cavities 344 while the gap settingmember 370 b is positioned between adjacent staple cavities 344. Each ofthe gap setting members 370 a, 370 b, 370 c extends across the elongateslot 343 in a direction perpendicular, or substantially perpendicular,to a longitudinal axis extending along the elongate slot 343. In otherinstances, one or more of the gap setting members 370 a, 370 b, 370 cmay not extend across the elongate slot 343. In various instances, thestaple cartridge 340″ may comprise more or less than three gap settingmembers, for example.

Referring now to FIGS. 18 and 19, staple cartridges 440 and 440′ aredepicted. The staple cartridges 440 and 440′ are similar in manyrespects to other staple cartridge disclosed herein such as, forexample, the staple cartridge 240. For example, the staple cartridges440 and 440′ comprise a cartridge body 442, a cartridge deck 445, staplecavities 444, a proximal portion 346, a distal portion 347, and anelongate slot 343 extending longitudinally from the proximal portion 346to the distal portion 347. The cartridge deck 445 includes steps 445′,445″ that define stepped deck surfaces 445 a, 445 b, 445 c. The staplecavities 444 are arranged in rows 444 a, 444 b, 44 c which are definedin deck surfaces 445 a, 445 b, 445 c, respectively.

Referring to FIG. 18, the staple cartridge 440 comprises gap settingpins 470 configured to set a minimum forming gap between the staplecartridge 440 and an anvil 250. In a fully closed configuration, theanvil 250 is configured to rest against the gap setting pins 470. Apredetermined minimum gap is set between the anvil 250 and the cartridgedeck 445 by the gap setting pins 470 in the fully closed configuration.

The gap setting pins 470 are positioned at a distal portion 347 of thestaple cartridge 440. Said another way, the gap setting pins 470 arepositioned distal to the staple cavities 444. As illustrated in FIG. 18,the gap setting pins 470 comprise a cylindrical, or at leastsubstantially cylindrical, shape, and are positioned on opposite sidesof a plane defined by the elongate slot 343. The gap setting pins 470are equidistant from the elongate slot 343 to balance the anvil 250 inthe closed configuration and resist any tilting that may occur in theanvil 250 as the anvil 250 is pressed against tissue captured betweenthe anvil 250 and the staple cartridge 440. The number, height, size,arrangement, and/or shape of the gap setting pins 470 can be selected toset a suitable minimum gap between the anvil 250 and the cartridge deck445.

The gap setting members 370 and or the gap setting pins 470 can be madefrom a plastic or a ceramic material. In certain instances, the gapsetting members 370 and or the gap setting pins 470 may comprise one ormore biocompatible elastomeric polymers. In certain instances, the gapsetting members 370 and or the gap setting pins 470 are made, or atleast partially made, from a medical grade plastic material. In certaininstances, the gap setting members 370 and or the gap setting pins 470are made, or at least partially made, from one or more resilientmaterials. In certain instances, the gap setting members 370 and or thegap setting pins 470 are more flexible than the cartridge deck 345 toensure an atraumatic interaction with the tissue.

Referring to FIG. 19, the staple cartridge 440′ comprises a shell 402configured to receive a cartridge body 442. Retention features 403 and405 secure the cartridge body 442 to the shell 402. To assemble thecartridge body 442 with the shell 402, the cartridge body 442 isinserted into the shell 402 until the retention features 403 and 405snap into engagement with corresponding openings 404 and 406 in theshell 402. Furthermore, the shell 402 includes elevated portions 480that extend above the cartridge deck 445 to set a minimum gap betweenthe cartridge deck 445 and an anvil 250 in a fully closed configuration.The elevated portions 480 comprise distal flanges 480 a and intermediateflanges 480 b that protrude through corresponding openings 481 a, 481 bin the cartridge deck 445. The distal flanges 480 a and intermediateflanges 480 b are bent away from the elongate slot 343. The elevatedportions 480 further include proximal flanges 482 that are bent towardthe elongated slot 343. Other elevated portions suitable for maintaininga minimum gap between the cartridge deck 445 and the anvil 250 in afully closed configuration can be utilized.

Referring now to FIGS. 20-21, a staple retainer 502 is affixed to acartridge deck 545 of a staple cartridge 540. The staple retainer 502extends between a proximal end 546 and a distal end 547 of the staplecartridge 540. The staple retainer 502 may be configured to mimic thesurface of the cartridge deck 545. The staple cartridge 540 comprises anelongate slot 543 centered among rows of staple cavities 544. Theelongate slot 543 may be configured to receive a cutting member. Thestaple retainer 502 may be labeled with various information to assistthe surgeon in selecting the appropriate cartridge for use with thesurgical instrument. Such information can also include descriptionsregarding the orientation of the staple cartridge 540 or instructionsfor attachment or removal of the staple retainer 502.

It is desirable to secure the staple retainer 502 to the staplecartridge 540 to ensure that the staples of the staple cartridge 540remain within their respective staple cavities 544. The staple retainer502 may be secured to the staple cartridge 540 through various meansincluding a biasing member in the form of a spring latch 501. The springlatch 501 includes two eject arms 506 and a hairpin retainer 507. Thehairpin retainer 507 can be configured to pass through an aperture 508on the proximal end 546 of the staple retainer 502 that is aligned withthe elongate slot 543 of the staple cartridge 540. Thus, the hairpinretainer 507 passes into the elongate slot 543 when the staple retainer502 is attached to the staple cartridge 540. The two eject arms 506 ofthe spring latch 501 may engage with a pair of wire cleats 505,configured to secure and retain the eject arms 506. As illustrated, thespring latch 501 may be located on the proximal end 546 of the stapleretainer 502. However, a spring latch 501 can be located on the distalend 547 of the staple retainer 502. Other suitable positions for thespring latch 501 are contemplated by the present disclosure.

Additional attachment features, including side wings or flanges 510, areutilized to strengthen the retention connection of the staple retainer502 to the staple cartridge 540. Such flanges 510 may contactcorresponding indentations on the cartridge body 542 of the staplecartridge 540. Flanges 510 may engage with the cartridge body 542 invarious ways, including but not limited to snap-fit or pressure-fitconnections, for example.

The staple retainer 502 further comprises a handle portion 520 forfacilitating removal of the staple retainer 502 from the staplecartridge 540. The handle portion 520 extends past the end of the staplecartridge 540 to facilitate grasping the handle portion 520. As alifting motion is applied to the handle 520, the upward forces canovercome the retention forces holding the spring latch 501 in place.Such upward forces are also capable of overcoming any additionalretention forces from the side wings or flanges 510.

Referring now to FIGS. 22-23, the elongate slot 543 of the staplecartridge 540 comprises inner sidewalls 550 with channel detents 551 tofacilitate the retention of the hairpin retainer 507 of the spring latch501. The hairpin retainer 507 has outward-extending curves that fitwithin the channel detents 551 on the inner sidewalls 550 of theelongate slot 543. As illustrated in FIG. 22, when holding the stapleretainer 502 in place, the hairpin retainer 507 is configured to enterthe elongate slot 543 to a degree where the staple retainer 502 liesflush against the cartridge deck 545 of the staple cartridge 540. Inthis position, a portion of the hairpin retainer 507 extends beyond thechannel detents 551 of the sidewalls 550, while the eject arms 506 restin the wire cleats 505 of the staple retainer 502.

As illustrated in FIG. 23, when the surgeon begins to lift up on thehandle 520 of the staple retainer 502, the staple retainer 502 pressesup against the eject arms 506 of the spring latch 501. When the ejectarms 506 are subjected to such an upward ejection force, they begin tobuckle inwardly, disengaging the hairpin retainer 507 from itsconnection with the channel detents 551 of the elongate slot 543. Thespring latch 501 may remain attached to the staple retainer 502throughout attachment and detachment because of the retention of theeject arms 506 within the wire cleats 505. This ensures that the springlatch 501 is removed with the staple retainer 502.

Referring now to FIGS. 24-28, a staple cartridge 640 is similar in manyrespects to other staple cartridges disclosed herein such as, forexample, the staple cartridges 240, 440. For example, the staplecartridge 640 comprises a cartridge body 642, a cartridge deck 645,staple cavities 644, staples 600, a proximal portion 346, a distalportion 347, and an elongate slot 343 extending longitudinally from theproximal portion 346 to the distal portion 347. The cartridge deck 645includes steps 645′, 645″ that define stepped deck surfaces 645 a, 645b, 645 c. The staple cavities 444 are arranged in rows 444 a, 444 b, 44c which are defined in the stepped deck surfaces 445 a, 445 b, 445 c,respectively.

As illustrated in FIG. 24, the staple cartridge 640 further comprises aplurality of staple drivers 602, 603, 604 which can each be configuredto support one or more staples 600 (FIG. 27) within the staple cavities444 when the staples 600 and the staple drivers 602, 603, 604 are intheir predetermined starting positions. Each of the staple drivers 602,603, 604 comprises cradles, or troughs, 607, for example, which areconfigured to support the staples 600. A staple-firing sled can be movedfrom a proximal portion 346 to a distal portion 347 of the staplecartridge 640 in order to sequentially lift the staple drivers 602, 603,604 and the staples 100 from their predetermined starting positionstoward an anvil 250 positioned opposite the staple cartridge 640.

As illustrated in FIG. 25, the staple drivers 602, 603, 604 are arrangedin different regions of the cartridge body 642. A proximal region 646includes the staple drivers 602 which comprise each two pushers 602 a,602 b supporting two staples 600 in the inner and intermediate cavityrows 644 a, 644 b. In addition, an intermediate region 649 includes thestaple drivers 603 which comprise each three pushers 603 a, 603 b, 603 csupporting three staples 600 in the inner, intermediate, and outercavity rows 644 a, 644 b, 644 c. Furthermore, a distal region 647includes the staple drivers 604 which comprise each four pushers 604 a,604 b, 604 c supporting four staples 600 in the inner, intermediate, andouter cavity rows 644 a, 644 b, 644 c.

Like the staple cartridge 440, the staple cartridge 640 comprises anouter shell that defines a bottom surface of the staple cartridge 640.During assembly, staple drivers 602, 603, 604 are inserted intopredetermined starting positions within the cartridge body 642. Then,the cartridge body 642 is assembled with the outer shell of the staplecartridge 640. To minimize shifting of the staple drivers 602, 603, 604from their predetermined starting positions, which occur during and/orafter the assembly process, the present disclosure provides variousretention features that are configured to maintain the assembled stapledrivers 602, 603, 604 at their predetermined starting positions. This isespecially useful in staple cartridges such as the staple cartridge 640where multiple staples from different deck surfaces are configured to besimultaneously driven by the same staple driver. Minor shifting motionof such staple drivers from their predetermined starting positions maycompromise the alignment of the staples with the staple driver which cancompromise the successful deployment of the staples.

FIG. 25 illustrates the staple cartridge 640 with the outer shell beingremoved exposing the staple drivers 602, 603, 604. The cartridge body642 comprises deformable or crushable retention features 610 thatmaintain the staple drivers 602, 603, 604 in their predeterminedstarting positions, as illustrated in FIG. 25. The deformable retentionfeatures 610 project or protrude from the staple drivers 602, 603, 604and/or in the cartridge body 642 providing a friction fit between thestaple drivers 602, 603, 604 and the cartridge body 642. In addition,the deformable retention features 610 extend along a predefineddirection of motion of the staple drivers 602, 603, 604 within thestaple cavities 644. In various instances, the deformable retentionfeatures 610 can be in the form of ribs or columns extending in adirection transverse to a plane defined by the cartridge deck 645. Adeformable retention feature 610 may comprise a dome-shaped ortriangular cross-sectional area. Other suitable shapes and sizes of thedeformable retention features 610 can be utilized.

The deformable retention features 610 may comprise the same materialcomposition as the cartridge body 642 and/or the staple drivers 602,603, 604. Alternatively, the deformable retention features 610 maycomprise a different material composition than the cartridge body 642and/or the staple drivers 602, 603, 604. The deformable retentionfeatures 610 are sized and positioned such that they are partiallydeformed to create the friction fit needed to maintain the stapledrivers 602, 603, 604 in their predetermined starting positions. Whenthe staple drivers 602, 603, 604 are in their predetermined startingpositions, an interference 611 between the deformable retention features610 and corresponding staple drivers 602, 603, 604 is about 0.001″ toabout 0.002″. That said, any suitable interference between thedeformable retention features 610 and corresponding staple drivers 602,603, 604 can be implemented. A suitable interference is one thatmaintains the staple drivers 602, 603, 604 in their predeterminedstarting positions but can be overcome by a staple deployment force or afiring force transmitted by a sled as the sled is advanced to motivatethe staple drivers 602, 603, 604 to deploy the staples 600.

The deformable retention features 610 are slightly plastically deformedbetween the staple drivers 602, 603, 604 and the cartridge body 642.Elastic recovery of deformable retention features 610 around the edgesof the staple drivers 602, 603, 604 maintain the staple drivers 602,603, 604 at the predetermined starting position. In certain instances,the plastic deformation of the deformable retention features 610 isselected from a range of about 1% to about 40%. In certain instances,the plastic deformation of the deformable retention features 610 isselected from a range of about 5% to about 35%. In certain instances,the plastic deformation of the deformable retention features 610 isselected from a range of about 10% to about 30%.

In certain instances, a suitable interference can be selected from arange of about 0.0015″ to about 0.003″, for example. In certaininstances, a suitable interference can be selected from a range of about0.0013″ to about 0.0017″, for example. In certain instances, a suitableinterference can be selected from a range of about 0.0014″ to about0.0016″, for example. In certain instances, the deformable retentionfeatures 610 are molded on the staple drivers 602, 603, 604 and/or inthe cartridge body 642. In certain instances, the deformable retentionfeatures 610 are attached to the staple drivers 602, 603, 604 and/or thecartridge body 642, for example. Any suitable manufacturing techniquescan be utilized to prepare staple drivers 602, 603, 604 and/or cartridgebodies 642 that include the deformable retention features 610.

Referring to FIG. 24, the external pushers 602 c, 603 c, 604 c, 604 dthat support staples 600 in the outer row of staple cavities 644 ccomprise clearance tracks, recesses, or slots 605 that are configured toreceive the deformable retention features 610. To assemble the staplecartridge 640, the outer pan or shell is removed, and the staple drivers602, 603, 604 are inserted into their predetermined starting positions.The clearance slots 605 are slid against the deformable retentionfeatures 610 extending or protruding from side walls 608 of the staplecavities 644 c. This causes deformation of the deformable retentionfeatures 610 as the staple drivers 604 are moved toward theirpredetermined starting positions. When a pusher such as, for example,the pusher 604 c is at its predetermined starting position, the elasticrecovery of deformed portions 610 a, 610 b of the deformable retentionfeatures 610 that are below a bottom surface 612 of the clearance slots605 and above a top surface 612 of the clearance slots ensures that thestaple drivers 602, 603, 604 remain at their predetermined startingpositions in the absence of a firing force. The portions 610 a, 610 bpartially wrap around the surfaces 606 and 612 of the staple drivers602, 603, 604 at their predetermined starting positions resistingexposure of the staple drivers 602, 603, 604 to shifting motions thatmay occur during and/or after assembly of the staple cartridge 640.

In addition to the retention benefits, the clearance slots 605 cooperatewith corresponding deformable retention features 610 to define a trackthat facilitates guiding the staple drivers 602, 603, 604 within thecartridge body 642 to their predetermined starting positions. In certaininstances, however, the staple drivers 602, 603, 604 may lack theclearance slots 605. In such instances, the deformable retentionfeatures 610 can provide an interference 611 against other portions ofthe staple drivers 602, 603, 604.

Further to the above, the clearance slots 605 need not be limited toexternal pushers 602 b, 603 c, 604 c, 604 d. Other pushers such as, forexample, pushers 602 a, 603 a, 603 b, 604 a, 604 b may compriseclearance slots 605 which can be pressed against correspondingdeformable retention features 610 in the cartridge body 642, forexample.

As illustrated in FIGS. 24 and 26, the clearance slots 605 extend alongthe entire height of the pushers 602 c, 603 c, 604 c, 604 d terminatingat top surfaces 612 and bottom surfaces 606. In other instances, aclearance slot 605 can extend along a portion of the height of a pusher,for example. Furthermore, as illustrated in FIGS. 27, 28, the deformableretention features 610 extend along the entire height of correspondingstaple cavities 644. Alternatively, a deformable retention feature 610may extend along a portion of the height of a staple cavity 644. Invarious instances, the clearance slots 605 and corresponding deformableretention features 610 comprise complimenting shapes to facilitate amating engagement therebetween.

In various instances, a cartridge body may include a retention featuresized such that a friction fit is defined between the retention featureand a corresponding clearance slot of a staple driver without visibledeformation of the retention feature. The retention feature maygradually increase in size from an initial portion at point of firstengagement between the retention feature and the clearance slot to anend portion at a point of last engagement between the retention featureand the clearance slot. The end portion comprises a largercross-sectional area than the initial portion to provide an appropriatefriction fit to maintain the staple driver at a predetermined startingposition. The size gradient allows the clearance slot 605 to easilyslide against a relatively narrow initial portion of the retentionfeature. A greater friction is realized between the clearance slot andthe retention feature as the size of the retention feature increases onthe way toward the predetermined starting position at the end portion.

In various instances, the staple drivers comprise the deformableretention features while the cartridge body comprises the correspondingclearance slots. As illustrated in FIG. 29, a staple driver such as, forexample, the staple driver 604′ comprises deformable retention features610 disposed on side walls of the pushers 604 c, 604 d in place of theclearance slots. A cartridge body may include corresponding clearanceslots configured to receive the deformable retention features 610 of thestaple driver 604′.

Referring now to FIGS. 30-32, a staple cartridge 740 is similar in manyrespects to other staple cartridges disclosed herein such as, forexample, the staple cartridges 240, 440, 640. For example, the staplecartridge 640 comprises a cartridge body 742, a cartridge deck 745,staple cavities 744, a proximal portion 346, a distal portion 347, andan elongate slot 343 extending longitudinally from the proximal portion346 to the distal portion 347. The cartridge deck 745 includes steps745′, 745″ that define stepped deck surfaces 745 a, 745 b, 745 c. Thestaple cavities 744 are arranged in rows 744 a, 744 b, 744 c which aredefined in the stepped deck surfaces 745 a, 745 b, 745 c, respectively.

Like the staple cartridge 240, the staple cartridge 740 comprisesstaples 100 (FIG. 30) that are removably stored in staple cavities 744.The staples 100 of the staple cartridge 740 are ejected from the staplecavities 744 by a firing member or sled 709 (FIG. 31) when the sled 709is moved from the proximal portion 746 of the cartridge body 642 towardthe distal portion 747. The sled 709 directly engages a base portion 130of the staples 100 to sequentially lift the staples 100 from theirpredetermined starting positions in the staple cavities 744 toward ananvil 250 positioned opposite the staple cartridge 740.

As illustrated in FIG. 30, the cartridge body 742 comprises deformableor crushable retention features 710, which are similar in many respectsto the deformable retention features 610. The deformable retentionfeatures 710 are configured to maintain the staples 100 in theirpredetermined starting positions in the absence of a firing force. Thedeformable retention features 710 project or protrude from the staples100 and/or the cartridge body 742 providing a friction fit between thestaples 100 and the cartridge body 742. In addition, the deformableretention features 710 extend along a predefined direction of motion ofthe staples within the staple cavities 744. In various instances, thedeformable retention features 710 can be in the form of ribs or columnsextending in a direction transverse to a plane defined by the cartridgedeck 745. A deformable retention feature 710 may comprise a dome-shapedor triangular cross-sectional area. Other suitable shapes and sizes ofthe deformable retention features 610 can be utilized. As illustrated inFIG. 31, the deformable retention features 710 protrude from side walls708 of the staple cavities 744 providing a friction fit between the baseportions 130 of the staples 100 and the cartridge body 742 at thepredetermined starting positions of the staples 100.

The deformable retention features 710 may comprise the same materialcomposition as the cartridge body 742 and/or base portions 130.Alternatively, the deformable retention features 710 may comprise adifferent material composition than the cartridge body 742 and/or thebase portions 130. The deformable retention features 710 are sized andpositioned such that they are partially deformed to create the frictionfit needed to maintain the staples 100 in their predetermined startingpositions. When the staples 100 are at their predetermined startingpositions, an interference 711 is defined between the deformableretention features 710 and corresponding base portions 130, and ismeasured at about 0.001″ to about 0.002″. That said, any suitableinterference between the deformable retention features 710 andcorresponding base portions 130 can be implemented. A suitableinterference is one that maintains the staples 100 in theirpredetermined starting positions but can be overcome by a stapledeployment force or a firing force transmitted by the sled 709 (FIG. 31)as the sled 709 is advanced against the base portions 130 to deploy thestaples 100.

The deformable retention features 710 are slightly plastically deformedbetween the base portions 130 of the staples 100 and the cartridge body742 at the predetermined starting positions. Elastic recovery ofdeformable retention features 710 around the edges of the base portions130 maintains the staples 100 at the predetermined starting positions.In certain instances, the plastic deformation of the deformableretention features 710 is selected from a range of about 1% to about40%. In certain instances, the plastic deformation of the deformableretention features 710 is selected from a range of about 5% to about35%. In certain instances, the plastic deformation of the deformableretention features 710 is selected from a range of about 10% to about30%.

In certain instances, a suitable interference between the deformableretention features 710 and corresponding base portions 130 can beselected from a range of about 0.0015″ to about 0.003″, for example. Incertain instances, a suitable interference between the deformableretention features 710 and corresponding base portions 130 can beselected from a range of about 0.0013″ to about 0.0017″, for example. Incertain instances, a suitable interference between the deformableretention features 710 and corresponding base portions 130 can beselected from a range of about 0.0014″ to about 0.0016″, for example.

In various instances, a surgical stapling and cutting instrument caninclude a pair of cooperating elongate jaw members, wherein each jawmember can be adapted to be inserted into a patient and positionedrelative to tissue that is to be stapled and/or incised. One of the jawmembers can support a staple cartridge with at least two laterallyspaced rows of staples contained therein. Examples of suitable staplecartridges include but are not limited to the staple cartridges 240(FIG. 5), 340 (FIG. 12), 440 (FIG. 18), 640 (FIG. 24). In addition, theother jaw member can support an anvil 850 (FIG. 33) with staple-formingpockets 856 (FIG. 33) aligned with the rows of staples in the staplecartridge.

Further to the above, the surgical stapling and cutting instrument canfurther include a firing assembly 800 (FIG. 35) which is slidablerelative to the jaw members to sequentially eject the staples from thestaple cartridge. During a firing stroke, the firing assembly 800 isconfigured to activate a plurality of staple drivers carried by thecartridge and associated with the staples in order to push the staplesagainst the staple-forming pockets 856 of the anvil 850 and formlaterally spaced rows of deformed staples in the tissue gripped betweenthe jaw members.

A spent staple cartridge, which has been fired, can be removed andreplaced with an unspent or unfired staple cartridge to allow thesurgical stapling and cutting instrument to be reused. A limitation tothe repeated use of a surgical stapling and cutting instrument arisesfrom damage sustained by the anvil from interfacing a firing assembly800 during a firing stroke. Anvils are typically manufactured frommaterials that can be easily stamped to create staple forming pockets.The material properties that allow anvils to be easily stamped reduce ananvil's resistance to the forces transmitted by the firing assembly 800during the firing stroke.

The present disclosure provides an anvil 850 that is designed to resistdamage caused by repeated firing of a surgical stapling and cuttinginstrument. As illustrated in FIG. 33, the anvil 850 is assembled from aplurality of discrete pieces that are designed to provide a localizedreinforcement to portions of the anvil 850 that interface with thefiring assembly 800 during a firing stroke. The reinforcement can be inthe form of localized, strengthening, hardening, coating, and/orlaminating of specific portions of the anvil 850, as described below ingreater detail.

Referring to FIG. 33, the anvil 850 includes a first forming portion854, a second forming portion 855, and a cover portion 851interconnecting the first forming portion 854 and the second formingportion 855. The anvil 850 includes an anvil channel 857. The firingassembly 800 slidingly travels along the anvil channel 857 during afiring stroke. The anvil channel 857 includes an elongate slot 866extending between the first forming portion 854 and the second formingportion 855. The elongate slot 866 inwardly opens along a longitudinalaxis of the anvil 850.

Further to the above, the anvil channel 857 includes a first recess 867defined between the cover portion 851 and the first forming portion 854.In addition, a second recess 868 of the anvil channel 857 is definedbetween the cover portion 851 and the second forming portion 855. Thefirst recess 867 and the second recess 868 are sized to receive a firstengagement portion 811 (FIG. 35) and a second engagement portion 812(FIG. 35), respectively, of an engagement member 810 (FIG. 35) of thefiring assembly 800.

Referring again to FIG. 33, a first reinforcement member 860 is attachedto the first inner interface 858 of the first forming portion 854, andthe second reinforcement member 861 is attached to a second innerinterface 859 of the second forming portion 855. In addition,staple-forming pockets 856 are stamped into a first outer interface 858of the first forming portion 854 and a second outer interface 859 of thesecond forming portion 855. During a firing stroke, the first engagementportion 811 and the second engagement portion 812 slidingly engage thefirst reinforcement member 860 and the second reinforcement member 861,respectively, as the firing assembly 800 is advanced along the anvilchannel 857. The advancement of the firing assembly 800 causes theplurality of staples to be deployed into the tissue and to be deformedagainst the staple-forming pockets 856.

The reinforcement members 860, 861 protect the inner interfaces 858, 859from deformation that may be caused by the engagement portions 811, 812during a firing stroke. To do so, the reinforcement members 860, 861 aremore able to resist deformation than the forming portions 854, 855. Incertain instances, the reinforcement members 860, 861 are harder thanthe forming portions 854, 855. In certain instances, the reinforcementmembers 860, 861 are made from a material composition that is differentfrom the material composition of the forming portions 854, 855. Forexample, the reinforcement members 860, 861 from titanium while theforming portions 854, 855 are made or at least partially made fromstainless steel. Other suitable material compositions for thereinforcement members 860, 861 and the forming portions 854, 855 can beutilized.

Further to the above, the reinforcement members 860, 861 can be in theform of flat plates that are welded or mechanically bonded to the innerinterfaces 858, 859, respectively. The flat plates comprise a thicknessselected from a range of about 0.003″ to about 0.007″. In certaininstances, the flat plates comprise a thickness selected from a range ofabout 0.00″ to about 0.006″. In certain instances, the flat platescomprise a thickness of about 0.005″, for example.

Due to size limitations, the anvil 850 is assembled in a manner thatpermits inclusion of the reinforcement members 860, 861. The anvil 850is manufactured in separate portions 854, 855, 851 which are assembledafter attachment of the reinforcement members 860, 861 to the formingportions 854, 855, respectively. In a first step of assembly, the firstreinforcement member 860 is attached to the first inner interface 858 ofthe first forming portion 854, and the second reinforcement member 861is attached to the second inner interface 859 of the second formingportion 854. In a second step of assembly, the cover portion 851 isattached to the first forming portion 854 and the second forming portion855 at outer edges 852, 853, respectively.

Various attachment mechanisms can be utilized in assembly of the anvil850 including but not limited to various welding and/or mechanicalbonding techniques. In certain instances, laser welding is utilized inassembly of the anvil 850. For example, as illustrated in FIG. 33, spotlaser welding 863 is utilized in attachment of the reinforcement members860, 861 to the forming portions 854, 855. Due to size limitations, thespot laser welding 863 is performed prior to attachment of the coverportion 851 to the forming portions 854, 855, which can be achieved bycontinuous laser welding, for example, along the edges 852, 853.

In various instances, the reinforcement members 860, 861 and/or theinner interfaces 858, 859 can be treated to increase hardness andresistance to deformation. Various suitable treatments can be utilizedto increase hardness of the reinforcement members 860, 861 and/or theinner interfaces 858, 859. In certain instances, the reinforcementmembers 860, 861 and/or the inner interfaces 858, 859 can be plasmacoated, for example.

Referring to FIGS. 33 and 34, the cover portion 851 may experiencedeflective forces during a firing stroke. In certain instances,reinforcement members can be attached to an inner interface 862 of thecover portion 851 to protect against such deflective forces.Alternatively, as illustrated in FIG. 34, an anvil 850′ can be equippedwith a cover portion 851′ designed to resist the deflective forces thatare experienced during the firing stroke. The cover portion 851comprises an atraumatic semi-circular outer interface 869 thatfacilitates insertion into a treatment site. In addition, the coverportion 851 comprises a flat, or at least substantially flat, innerinterface 862′ which give the cover portion 851 a generally dome-shapedcross-sectional area that provides sufficient strength to resist thedeflective forces that are experienced during the firing stroke.

Referring to FIG. 35, the firing assembly 800 includes an I-beam 802extending distally from a laminated firing bar 804. The I-beam 802facilitates closure and firing of the surgical stapling and cuttinginstrument during a firing stroke. In addition to any attachmenttreatment such as brazing or an adhesive, the I-beam 802 and laminatedfiring bar 804 are formed of a female vertical attachment aperture 806distally formed in the laminated firing bar 804 that receives acorresponding male attachment member 807 proximally presented by theI-beam 802, allowing each portion to be formed of a selected materialand process suitable for their disparate functions (e.g., strength,flexibility, friction).

The I-beam 802 may be advantageously formed of a material havingsuitable material properties for forming a pair of top engagementportions or pins 811, 812 and a bottom pin or foot 113, as well as asharp cutting edge 814. The laminated firing bar 804 is formed of aplurality of layers or plates comprising different materialcompositions. As illustrated in FIG. 35, a laminated firing bar 804includes a first outer layer 820, a second outer layer 822, and anintermediate layer 821 sandwiched between the outer layers 820, 822. Theintermediate layer 821 comprises a thickness T2 that is greater than athickness T1 of the first outer layer 820, and greater than a thicknessT3 of the second outer layer 822. Furthermore, the thinner outer layers820, 822 could be stainless steel making them more flexible and lesscapable of buckling resistance with the intermediate layer 821 beingmade of titanium and therefore more buckle resistant. The layers 820,821, 822 can be made from other suitable materials. This design isparticularly useful in resisting fatigue failure with repetitive firingof the surgical stapling and cutting instrument.

In certain instances, the ratio of the thickness T2 of the intermediatelayer 821 to the thickness T1 of the first outer layer 820 is selectedfrom a range of about 95% to about 5%. In certain instances, the ratioof the thickness T2 of the intermediate layer 821 to the thickness T1 ofthe first outer layer 820 is selected from a range of about 80% to about30%. In certain instances, the ratio of the thickness T2 of theintermediate layer 821 to the thickness T1 of the first outer layer 820is selected from a range of about 60% to about 40%. Other values for theratio of the thickness T2 of the intermediate layer 821 to the thicknessT1 of the first outer layer 820 are contemplated by the presentdisclosure.

Referring to FIGS. 36-38, various attachment mechanisms are utilized toattach the intermediate layer 821 to the outer layers 820, 822. Incertain instances, various welding techniques are utilized in attachmentof the layers 820, 821, 822. As illustrated in FIG. 36, an aperture 824can be created in a laminated firing bar 804. The aperture 824 can becreated through each of the layers 820, 821, 822 thus defining a throughhole. The aperture 824 can be filled with melted portions of at leastone of the outer layers 821, 822 to bond the layers 820, 821, 822 of thelaminated firing bar 804. The aperture 824 is created by any suitabletechnique.

During assembly, the intermediate layer 821 is sandwiched between theouter layers 820, 822. In addition, portions of one or both of the outerlayers 820, 822 are melted and permitted to flow through the aperture824 to bridge the aperture 824 creating a bond between the layers 820,821, 822 as the melted material is actively cooled, or permitted to cooldown, to a temperature below a melting point. In certain instances, theouter layers 820, 822 are comprised of stainless steel that is melted tobridge the aperture 824.

In other instances, a filler material 826 can be utilized to bridge theaperture 824 and bond layers 820, 821, 822 of a laminated firing bar804″, as illustrated in FIG. 38. The filler material 826 can be insertedinto the aperture 824 either in a melted form or in an unmelted formthat is then melted within the aperture 824. The filler material 826 isthen actively cooled, or allowed to cool down, to a temperature belowthe melting point of the filler material 826 to bond the layers 820,821, 822.

Referring to FIG. 37, an attachment member 827 can be utilized to joinlayers or plates of a laminated firing bar 804′ comprised of differentmaterials. For example, the laminated firing bar 804′ comprises a layer820 made, or at least partially made, from stainless steel and a layer821 made, or at least partially made, from titanium. Other suitablematerials can be utilized. The attachment member 827 comprises a firstportion 827a greater in size than the aperture 824, and a second portion827b sized to be received within the aperture 824, as illustrated inFIG. 37. The attachment member 827 can be made, or at least partiallymade, from the same material as the layer 820. The laminated firing bar804′ is assembled by inserting the second portion 827b into the aperture824 such that the first portion 827a abuts against the layer 821. Heatcan then be introduced to partially melt at least a portion of thesecond portion 827b and/or a portion of the layer 820. Upon cooling to atemperature below the melting point, the resulting bond between thelayer 820 and the attachment member 827 provides an attachment betweenthe layers 820, 821.

Referring now to FIGS. 39 and 40, an end effector 900 of a surgicalstapling and cutting instrument includes a shaft portion 901, an anvil902 extending distally from the shaft portion 901, and an elongatechannel 911 movably coupled to the shaft portion 901. A staple cartridge940 is removably attached to the elongate channel 911. The staplecartridge 940 is similar in many respects to other staple cartridgesdisclosed herein such as, for example, the staple cartridge 240.

To operate the surgical stapling and cutting instrument, an unfiredstaple cartridge 940 is loaded by insertion into the elongate channel911. The end effector 900 is then positioned around tissue. A firing bar906 is then moved, during a firing stroke, to advance a firing assembly904 distally to transition the end effector 900 to a closedconfiguration to capture the tissue. In addition the firing assembly 904also causes staples from the staple cartridge 940 to be deployed intothe captured tissue. The firing assembly 904 further includes a distalcutting edge 908 extending distally from a body 905, and configured tocut the stapled tissue. In certain instances, however, the firingassembly 904 may not include a cutting edge 908. The firing bar 906extends proximally from the firing assembly 904 in a direction oppositethe cutting edge 908.

As illustrated in FIG. 39, the anvil 902 is fixedly attached to theshaft portion 901. In certain instances, however, the anvil 902 can bemovable relative to the shaft portion 901. In addition, the elongatechannel 911 is rotatable about a channel pivot 912 to transition thestaple cartridge 940 and the anvil 902 between an open configuration, asillustrated in FIG. 40, and a closed configuration, as illustrated inFIG. 39.

Further to the above, the firing assembly 904 further includes an anvilcamming member 907 and a channel camming member 909 which cooperate totransition the end effector 900 to a closed configuration. Asillustrated in FIG. 39, the anvil camming member 907 and the channelcamming member 909 are configured to slidingly engage the anvil 902 andthe elongate channel 911, respectively, as the firing assembly 904 isadvanced distally during a firing stroke. The firing assembly 904 maydistally translate a sled that facilitates the deployment of the staplesinto the captured tissue.

Upon completion of the firing stroke, the firing bar 906 is movedproximally to retract the firing assembly 904 to a neutral or dwellposition where the anvil camming member 907 and the channel cammingmember 909 are no longer able to apply camming forces to the anvil 902and the elongate channel 911. In other words, at the dwell position, theelongate channel 911 is free to open in order to release the stapledtissue. The end effector 900 can also be pulled away from the stapledtissue in order to free the stapled tissue. Yet, the spacing between theanvil 902 and the staple cartridge 940 at the dwell position may not besufficiently wide to facilitate an atraumatic release of the stapledtissue by pulling the end effector 904 away from the stapled tissue. Thepresent disclosure provided various mechanisms for positively openingthe end effector 900 to increase the spacing between the anvil 902 andthe staple cartridge 940 to facilitate an atraumatic release of thestapled tissue from the end effector 900.

Referring to FIGS. 39 and 40, the firing assembly 904 further comprisesan engagement portion 910 which is sized and positioned to engage acamming member 914 during retraction of the firing assembly 904 by thefiring bar 906. The engagement portion 910 is configured to motivate thecamming member 914 to positively open the elongate channel 911 as thefiring assembly 904 is moved proximally from the dwell position by thefiring bar 906. Positive opening of the elongate channel 911 entailsapplying an external force to the elongate channel 911 that cangradually open the end effector 900 to a fully open configurationdefined by a maximum spacing between the anvil 902 and a staplecartridge 940 attached to the elongate channel 911.

The gradual opening of the elongate channel 911 facilitates a gradualand/or controlled release of the stapled tissue from the end effector900 which can reduce the tissue trauma. Such gradual opening of theelongate channel 911 is achieved by gradually retracting the firing bar906 to move the firing assembly 904 proximally so that the engagementportion 910 gradually motivates the camming member 914 to gradually openthe elongate channel 911.

As illustrated in FIGS. 39 and 40, the engagement portion 910 isconfigured to engage a first portion 916 of the camming member 914 whichcauses rotation of the camming member 914 about a pivot 915. Therotation of the camming member 914 causes a second portion 917 of thecamming member 914 to slidingly engage a sloped surface 918 of an endportion 913 of the elongate channel 911. The end portion 913 ispositioned proximal to the channel pivot 912. Once the engagementportion 910 is in contact with the first portion 916 and the secondportion 917 is in contact with the end portion 913 of the elongatechannel 911, any further retraction of the firing assembly 904 by thefiring bar 906 results in a positive opening of the elongate channel911.

Accordingly, the firing assembly 904 is movable proximally from thedwell position to a first proximal position where the engagement portion910 contacts the first portion 916 of the camming member 914. The firingassembly 904 is also movable proximally from the first proximal positionto a second proximal position, further away from the dwell position thanthe first proximal position. The movement of the firing assembly 904toward the second proximal position causes the camming member 914 torotate about the pivot 915 until the second portion 917 of the cammingmember 914 is brought into contact with the end portion 18 of theelongate channel 911. The firing assembly 904 is also movable proximallyfrom the second proximal position to a third proximal position, furtheraway from the dwell position than the second proximal position. Themovement of the firing assembly 904 toward the second proximal positioncauses the camming member 914 to exert a camming force against the endportion 913 to positively open the elongate channel 911 which graduallytransitions the end effector 900 to a fully open configuration, asillustrated in FIG. 40.

As illustrated in FIG. 39, a first angle is defined between the secondportion 917 and the end portion 913 in the closed configuration. Inaddition, as illustrated in FIG. 40, a second angle is defined betweenthe second portion 917 and the end portion 913 in the openconfiguration, wherein the second angle is greater than the first angle.Furthermore, the end portion 913 is partially wrapped around the channelpivot 912 which cooperates with the second portion 917 to define amaximum open configuration, as illustrated in FIG. 40.

In certain instances, the firing assembly 904 is movable distally fromthe dwell position to a first distal position and a second distalposition further away from the dwell position than the first distalposition. The movement of the firing assembly 904 toward the firstdistal position causes the end effector 900 to be transitioned to aclosed configuration to capture tissue without deploying the staplesfrom the staple cartridge 940. In addition, the movement of the firingassembly 904 from the first distal position toward the second distalposition causes the staples to be deployed from the staple cartridge940. A user of the surgical stapling a cutting instrument can captureand release tissue multiple times until an optimal tissue portion iscaptured by advancing and retracting the firing assembly 904 between thefirst distal position and the third proximal position.

In various instances, the engagement portion 910 is manufactured as oneseamless piece with the firing assembly 904. In other instances, theengagement portion 910 can be coupled to the firing assembly 904 postmanufacturing. Various suitable techniques can be employed to attach theengagement portion 910 to the firing assembly 904 including but notlimited to welding, adhesives, and other mechanical, thermal, and/orchemical bonding techniques.

As illustrated in FIG. 39, the engagement portion 910 is coupled to thechannel camming member 909, and extends proximally in parallel, orsubstantially in parallel, with the firing bar 906. The engagementportion 910 comprises a blunt end-portion 903 oriented to engage thefirst portion 916 of the camming member 914 as the firing assembly 904is retracted proximally.

Further to the above, the camming member 914 comprises a triangular, orsubstantially triangular, cross-section. The first portion 916 extendsin a first direction and the second portion 917 extends in a seconddirection defining an obtuse angle with the first direction. In a closedconfiguration of the end effector 900, as illustrated in FIG. 39, thefirst portion 916 of the camming member 914 protrudes through ahorizontal plane defined by the elongate channel 911, wherein the firstportion 916 and the engagement portion 910 are on the same side of thehorizontal plane. In a fully open configuration of the end effector 900,as illustrated in FIG. 40, the engagement portion 910 rotates the firstportion 916 causing the second portion 917 to apply a camming forceagainst the end portion 913 of the elongate channel 911 to positivelyopen the elongate channel 911.

Referring now to FIGS. 41 and 42, an end effector 900′ is similar inmany respects to the end effector 900. For example, the end effector900′ includes a shaft portion 901, an anvil 902 extending distally fromthe shaft portion 901, and an elongate channel 911′ movably coupled tothe shaft portion 901. The end effector 900′ comprises a mechanism forpositively opening the elongate channel 911′ that similar in manyrespects to the positive opening mechanism of the end effector 900. Theend effector 900′ comprises a firing assembly 904′ comprising anengagement portion 910′ extending proximally in parallel, or at leastsubstantially in parallel, with the firing bar 906. The engagementportion 910′ comprises a sloped end-portion 903′ sized and oriented toengage a head piece 921 of a lever arm 920. The sloped end-portion 903′is configured to slide under the head piece 921 to lift the head piece921 toward a bottom surface 918′ of the end portion 913′ of the elongatechannel 911′.

In operation, the firing assembly 904′ is retracted proximally by thefiring bar 906 from the dwell position to a first proximal positionwhere the sloped end-portion 903′ establishes first contact with thehead piece 921 of the lever arm 920. An additional proximal retractionof the firing assembly 904 to a second proximal position, further awayfrom the dwell position than the first proximal position, causes thesloped end-portion 903′ to slide under the head piece lifting 921 thehead piece 921 toward an initial contact with a bottom surface 918′ ofthe end portion 913′ of the elongate channel 911′. An additionalproximal retraction of the firing assembly 904 to a third proximalposition, further away from the dwell position than the second proximalposition, causes the sloped end-portion 903′ to motivate the head piece921 to exert an opening force that rotates the end portion 913′ aboutthe channel pivot 912. This causes the elongate channel 911′ to open toa maximum open configuration that corresponds the head piece 921reaching, or at least substantially reaching, the peak of the slopedend-portion 903′.

The above-described positive opening mechanism protects the end effector900′ from excessive actuation forces that may be applied to the firingbar 906. Once a maximum open configuration is achieved, as illustratedin FIG. 42, an additional retraction of the firing assembly 904′ doesnot result in an additional lifting of the head piece 921 once the headpiece 921 reaches the peak of the slope end portion 903′.

Further to the above, the sloped end-portion 903′ permits a graduallifting of the head piece 921 as the sloped end-portion 903′ slidinglymoves with respect to head piece 921. This results in a gradual openingof the elongate channel 911′ minimizing the tissue trauma to the stapledtissue captured between the staple cartridge 940 and the anvil 902 asthe stapled tissue is released from the end effector 900′. The slope ofthe sloped end-portion 903′ can be adjusted to optimize the rate ofopening of the end effector 900′. A greater slope of the slopedend-portion 903′ generally corresponds to a greater rate of opening ofthe end effector 900′.

As illustrated in FIG. 41, the head piece 921 is positioned below ahorizontal plane defined by the elongate channel 911′ at a default orstarting position. As the firing assembly 904′ is retracted, theengagement portion 910′ lifts the head piece 921 into a slidingengagement with the bottom surface 918′ of the end portion 913′ of theelongate channel 911′. The head piece 921 is lifted in a directionperpendicular, or at least substantially perpendicular, to alongitudinal axis 922, as illustrated in FIG. 42. In various instances,the lever arm 920 is spring biased to return the head piece to thedefault or starting position when the head piece 921 is released fromthe sloped end-portion 903′.

In various instances, a disposable loading unit (DLU) for a surgicalstapling instrument can include an anvil, a staple cartridge, a staplecartridge channel for operably supporting the staple cartridge, and aconnector portion for removably attaching the DLU to the surgicalstapling instrument. A spent, or at least partially spent, staplecartridge can be replaced with a new staple cartridge facilitating useof the DLU in multiple firings. The repeated firing of the surgicalstapling instrument may subject the DLU to excessive forces. The presentdisclosure provides DLU connector portions that are designed towithstand such forces. Examples of surgical stapling instrumentssuitable for use with the DLUs of the present disclosure are describedin U.S. Patent Application Publication No. 2016/0249921 entitledSURGICAL APPARATUS WITH CONDUCTOR STRAIN RELIEF, and published Sep. 1,2016, which is hereby incorporated herein by reference in its entirety.

Referring to FIGS. 43-45, DLUs 1010, 1030, 1050 comprise connectorportions 1021, 1041, 1061, respectively, for releasable attachment to asurgical stapling instrument. The connector portions 1021, 1041, 1061are designed to withstand the forces transmitted during multiple firingsof a surgical stapling instrument. The connector portions 1021, 1041,1061 comprise hollow bodies 1015, 1035, 1055, respectively, extendingproximally from the DLUs 1010, 1030, 1050, respectively, along alongitudinal axis 1016. The hollow bodies 1015, 1035, 1055 areconfigured to accommodate actuation members that transmit actuationmotions to the end effectors of the DLUs 1010, 1030, 1050.

Referring to FIG. 43, the connector portion 1021 comprises pins orconnectors 1017, 1018, 1019, 1020 which protrude radially from thehollow body 1015. The pins or connectors 1017, 1018, 1019, 1020 areconfigured to establish a bayonet connection with the surgical staplinginstrument. The connector 1017 and the connector 1018 extend from thehollow body 1015 in opposite directions. Likewise, the connector 1019and the connector 1020 extend from the hollow body 1015 in oppositedirections. The hollow body 1015 comprises a first body portion 1012 anda second body portion 1014 on opposite sides of a plane that transectsthe hollow body 1015 and encompasses the longitudinal axis 1016. Theplane is further defined by an articulation link 1013 that is slidablypositioned between the first body portion 1012 and a second body portion1014 and is adapted to engage an articulation mechanism of the surgicalstapling instrument.

Further to the above, the connectors 1018, 1020 are spaced apart by afirst distance, and protrude from the first body portion 1012. Inaddition, the connectors 1017, 1019 are spaced apart by a seconddistance, and protrude from the second body portion 1014. The firstdistance is equal, or substantially equal, to the second distance. Asillustrated in FIG. 43, the connectors 1017, 1019 are positioneddistally relative to the connectors 1019, 1020. In certain instances,the first distance is different than the second distance. For example,the first distance can be greater than the second distance.Alternatively, the first distance can be less than the second distance.

Further to the above, the connectors 1017, 1018, 1019, 1020 protrudefrom the hollow body 1015 in directions that are perpendicular, or atleast substantially perpendicular, to the longitudinal axis 1016. Asillustrated in FIG. 43, the connectors 1017, 1018 are aligned with eachother defining a first axis 1022 intersecting the longitudinal axis1016. In addition, the connectors 1019, 1020 are aligned with each otherdefining a second axis 1023 that also intersects the longitudinal axis1016. A first angle is defined between the longitudinal axis 1016 andthe first axis 1022, and a second angle is defined between thelongitudinal axis 1016 and the second axis 1023, wherein the first angleis equal, or substantially equal, to the second angle. In certaininstances, the first angle and/or the second angle can be about 90° ,for example.

Furthermore, the connectors 1017, 1018, 1019, 1020 are symmetrical inshape and size. As illustrated in FIG. 43, the connectors 1017, 1018,1019, 1020 each comprises a rectangular cross-section. However,connectors with other suitable shapes and sizes can be employed.

Referring now to FIG. 44, the connector portion 1041 comprises pins orconnectors 1037, 1038, 1039, 1040 which protrude radially from thehollow body 1035. The connector 1037 and the connector 1038 extend fromthe hollow body 1035 in opposite directions. Likewise, the connector1039 and the connector 1040 extend from the hollow body 1035 in oppositedirections.

Further to the above, the connectors 1037, 1038, 1039, 1040 protrudefrom the hollow body 1035 in directions that are perpendicular, or atleast substantially perpendicular, to the longitudinal axis 1016. Asillustrated in FIG. 44, the connectors 1037, 1038 are aligned with eachother defining a first axis 1042 intersecting the longitudinal axis1016. In addition, the connectors 1039, 1040 are aligned with each otherdefining a second axis 1043 that also intersects the longitudinal axis1016. The first axis 1042 and the longitudinal axis 1016 define a planeintersected by the second axis 1043 at an angle of about 90°, forexample. In certain instances, the angle is selected from a range ofabout 0° to about 90°, for example.

As illustrated in FIG. 44, the connectors 1037, 1038 define a firstengagement portion 1032, and the connectors 1039, 1040 define a secondengagement portion 1034. The engagement portions 1032, 1034 are spacedapart, wherein the first engagement portion 1032 is distal to the secondengagement portion 1034. In addition, the first engagement portion 1032can be radially offset with respect to the second engagement portion1034. For example, as illustrated in FIG. 44, the first engagementportion 1032 is oriented at a 90° angle with respect to the secondengagement portion 1034 which provides a robust connection between theDLU 1030 and the surgical stapling instrument. Other suitableorientations of the first engagement portion 1032 with respect to thesecond engagement portion 1034 can be implemented.

Furthermore, the connectors 1037, 1038, 1039, 1040 are symmetrical inshape and size. As illustrated in FIG. 44, the connectors 1037, 1038,1039, 1040 each comprises a rectangular cross-section. However,connectors with other suitable shapes and sizes can be employed.

Referring to FIG. 45, the connector portion 1061 comprises couplingflanges 1052 and 1054 disposed radially about an outer wall 1053 of thehollow body 1055. The outer wall 1053 includes a first portion 1056 anda second portion 1057 that is radially offset from the first portion1056. The coupling flange 1052 protrudes from the first portion 1056while the coupling flange 1054 protrudes from the second portion 1057.The coupling flanges 1052, 1054 are spaced apart from each other anddefine distal end portions that are different distances away from theend effector of the DLU 1050. Alternatively, in certain instances, thecoupling flanges 1052, 1054 are combined into one seamless structure. Incertain instances, a distal end portion of the coupling flange 1052 ispositioned distally with respect to a distal end portion of the couplingflange 1054. In other instances, the distal end portion of the couplingflange 1052 is positioned proximally with respect to the distal endportion of the coupling flange 1054.

The coupling flanges 1052, 1054 are configured to establish a bayonetconnection with corresponding features of a surgical staplinginstrument. The coupling flanges 1052, 1054 cooperate with thecorresponding features to drive the DLU 1050 into a final position wherea proper connection is established between the DLU 1050 and the surgicalstapling instrument.

In various instances, one or more of the connector portions 1010, 1030,1050 can be manufactured by attaching a suitable ring around acorresponding hollow body. The ring can be manipulated to include thecorresponding connectors. Then, the ring can be secured around thehollow body. The ring can be heat staked in place, overmolded, or fixedin place through other suitable means. In various instances, the ringcan be a metal ring to improve the robustness of the connectionsportions 1010, 1030, 1050, for example.

Referring now to FIG. 46, an intermediate shaft assembly 1100 isreleasably attachable to a handle assembly and a DLU of a surgicalstapling instrument. Examples of handle assemblies and DLUs that aresuitable for use with the intermediate shaft assembly 1100 are disclosedin U.S. Patent Application Publication No. 2016/0095585, titled HANDHELDELECTROMECHANICAL SURGICAL SYSTEM, and filed Sep. 24, 2015, which ishereby incorporated by reference herein in its entirety. FIG. 46 alsodepicts portions of proximal portions of a suitable DLU 1110 that areattachable to corresponding distal portions of the intermediate shaftassembly 1100 as described below in greater detail.

The intermediate shaft assembly 1100 comprises a clutch assembly 1104configured to switch between an articulation output and a firing output.The clutch assembly 1104 comprises a shifter 1105 movable between afirst position, where a drive input yields the articulation output, anda second position, where the drive input yields the firing output. Thedrive input is applied to a proximal portion 1106 of a firing rod 1107.When the intermediate shaft assembly 1100 is coupled to a hand assembly,the proximal portion 1106 of the firing rod 1107 is operably coupled toa drive assembly of the handle assembly that includes a motor configuredto generate at least one rotational motion that is converted by thedrive assembly into at least one axial motion that provides the driveinput to the proximal portion 1106 of the firing rod.

Further to the above, a camming slot 1109 defined in an outer housing1111 of the intermediate shaft assembly 1100 is configured to motivatethe shifter 1105 to move between the first position and the secondposition. The outer housing 1111 is moved between a proximal positionand a distal position to transition a jaw assembly of the DLU 1110between an open configuration and a closed configuration. While the jawassembly is in in the open configuration, the shifter 1105 is at thefirst position, where an articulation mechanism 1112 is engaged with thefiring rod 1107 such that the drive input yields an articulation output.The articulation mechanism 1112 includes an articulation rod 1114 and anarticulation engagement portion 1115 releasably coupled to acorresponding articulation engagement portion 1116 of the DLU 1110.

While the shifter 1105 is in the first position, the articulation rod1114 is movable with the firing rod 1107 in response to the drive input.The movement of the firing rod 1107 in this stage is not sufficient toyield a firing output. However, the movement of the firing rod 1107 issufficient to yield an articulation output by motivating thearticulation engagement portion 1115 to cause articulation engagementportion 1116 of the DLU 1110 to be advanced distally, which causesarticulation of the DLU 1110 about a longitudinal axis 1103 of theintermediate shaft assembly 1100.

Further to the above, as the outer housing is advanced distally totransition the jaw assembly of the DLU 1110 to a closed configuration,the shifter 1105 is transition to the second position which causesrotation of a clutch 1117. The rotation of the clutch 1117 disengagesthe firing rod 1107 from the articulation mechanism 1112 such that thedrive input yields the firing output. The firing rod 1107 includes adistal portion 1108 releasably couplable to a firing mechanism 1120 ofthe DLU 1110. As illustrated in FIG. 46, the firing mechanism 1120comprises an inner housing 1122 and a flexible drive beam 1119 having aproximal engagement section 1121 that includes diametrically opposedinwardly extending fingers that are configured to secure the distalportion 1108 of the firing rod 1107 to the flexible drive beam 1119.While the shifter 1105 is in the second position, the articulationmechanism 1112 is disengaged from the firing rod 1107, and advancementof the firing rod 1107 causes the firing mechanism 1120 to deploy aplurality of staples from a staple cartridge of the jaw assembly of theDLU 1110.

EXAMPLES Example 1

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody, a plurality of staple cavities, a plurality of staples housed inthe cartridge body, and a sled. The cartridge body comprises a proximalportion, a distal portion, and an elongate slot extending between theproximal portion and the distal portion, and a bottom surface. Thecartridge body further comprises a cartridge deck on an opposite side ofthe cartridge body from the bottom surface. The cartridge deck comprisesa first deck surface, and a second deck surface laterally offset fromthe first deck surface in a direction away from the elongate slot,wherein the first deck surface is stepped up from the second decksurface relative to the bottom surface. The plurality of staple cavitiescomprise a first row of staple cavities defined in the first decksurface, and a second row of staple cavities defined in the second decksurface, wherein the first row of staple cavities is closer to theelongate slot than the second row of staple cavities. The plurality ofstaples comprise first staples deployable from the first row of staplecavities, and second staples deployable from the second row of staplecavities. Each of the plurality of staples comprises a base comprisingan inclined drive surface, a first leg extending from the base, and asecond leg extending from the base, wherein the base, the first leg andthe second leg define a seamless unitary piece, and wherein the firstlegs of the first staples and the first legs of the second staplescomprise different unformed heights. The sled comprises a first rampconfigured to directly engage the inclined drive surface of the firststaples to deploy the first staples from the first row of staplecavities, wherein the first ramp is configured to cooperate with theanvil to form the first staples to a first formed height, and a secondramp configured to directly engage the inclined drive surface of thesecond staples to deploy the second staples from the second row ofstaple cavities, wherein the second ramp is configured to cooperate withthe anvil to form the second staples to a second formed height greaterthan the first formed height.

Example 2

The staple cartridge assembly of Example 1, wherein the inclined drivesurface is positioned intermediate the first leg and the second leg.

Example 3

The staple cartridge assembly of Examples 1 or 2, wherein the first legand the second leg define a leg plane, wherein the inclined drivesurface defines a drive plane, and wherein the drive plane is offsetfrom the leg plane.

Example 4

The staple cartridge assembly of Examples 1, 2, or 3, wherein the baseis asymmetrical.

Example 5

The staple cartridge assembly of Examples 1, 2, 3, or 4, wherein thefirst ramp and the second ramp comprise different heights.

Example 6

The staple cartridge assembly of Examples 1, 2, 3, 4, or 5, wherein thefirst ramp comprises a first peak surface, wherein the second rampcomprises a second peak surface, and wherein the first peak surface ishigher than the second peak surface.

Example 7

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody, a plurality of staple cavities, a plurality of staples housed inthe cartridge body, and a sled. The cartridge body comprises a proximalportion, a distal portion, and an elongate slot extending between theproximal portion and the distal portion. The cartridge body furthercomprises a cartridge deck. The cartridge deck comprises a first decksurface defining a first deck height, and a second deck surface defininga second deck height, wherein the second deck height is shorter than thefirst deck height. The plurality of staple cavities comprise a first rowof staple cavities defined in the first deck surface; and a second rowof staple cavities defined in the second deck surface, wherein the firstrow of staple cavities is closer to the elongate slot than the secondrow of staple cavities. The plurality of staples comprise first staplesdeployable from the first row of staple cavities, wherein each of thefirst staples comprise an unformed height, and second staples deployablefrom the second row of staple cavities, wherein each of the secondstaples comprise the unformed height. Each of the plurality of staplescomprises a base comprising a sloping drive surface, a first legextending from the base, and a second leg extending from the base,wherein the first leg and the second leg define a first plane, whereinthe drive surface extends along a portion of the base in a directionparallel to the first plane, wherein the sloping drive surface islaterally offset from the first plane. The sled comprises a first rampconfigured to directly engage the sloping drive surface of the firststaples to deploy the first staples from the first row of staplecavities, wherein the first ramp is configured to cooperate with theanvil to form the first staples to a first formed height, and a secondramp configured to directly engage the sloping drive surface of thesecond staples to deploy the second staples from the second row ofstaple cavities, wherein the second ramp is configured to cooperate withthe anvil to form the second staples to a second formed height greaterthan the first formed height.

Example 8

The staple cartridge assembly of Example 7, wherein the sloping drivesurface is positioned intermediate the first leg and the second leg.

Example 9

The staple cartridge assembly of Examples 7 or 8, wherein the first legand the second leg define a leg plane, wherein the sloping drive surfacedefines a drive plane, and wherein the drive plane is offset from theleg plane.

Example 10

The staple cartridge assembly of Examples 7, 8, or 9, wherein the baseis asymmetrical.

Example 11

The staple cartridge assembly of Examples 7, 8, 9, or 10, wherein thefirst ramp and the second ramp comprise different heights.

Example 12

The staple cartridge assembly of Examples 7, 8, 9, 10, or 11, whereinthe first ramp comprises a first peak surface, wherein the second rampcomprises a second peak surface, and wherein the first peak surface ishigher than the second peak surface.

Example 13

The staple cartridge assembly of Examples 7, 8, 9, 10, 11, or 12,wherein the base, the first leg, and the second leg define a unitarypiece.

Example 14

A surgical stapling instrument comprising an anvil, a staple cartridge,and a sled. The anvil comprises a first row of pockets, and a second rowof pockets, and at least one of the anvil and the staple cartridge ismovable relative to the other between an open configuration and a closedconfiguration to capture tissue. The staple cartridge comprises acartridge body, wherein the cartridge body comprises a proximal portion,a distal portion, and an elongate slot extending between the proximalportion and the distal portion. The cartridge body further comprises acartridge deck, wherein the cartridge deck comprises a first decksurface, and a second deck surface positioned further away from theelongate slot than the first deck surface. The plurality of staplecavities comprise a first row of staple cavities defined in the firstdeck surface, wherein a first gap is defined between the first row ofpockets and the first row of staple cavities in the closedconfiguration, and a second row of staple cavities defined in the seconddeck surface, wherein the first row of staple cavities is closer to theelongate slot than the second row of staple cavities, wherein a secondgap is defined between the second row of pockets and the second row ofstaple cavities in the closed configuration, and wherein the second gapis greater than the first gap. The plurality of staples comprise firststaples deployable from the first row of staple cavities, wherein thefirst staples comprise a first unformed height, and second staplesdeployable from the second row of staple cavities, wherein the secondstaples comprise a second unformed height greater than the firstunformed height. Each of the plurality of staples comprises a leg, andan integral drive surface. The sled comprises a first ramp configured todirectly engage the integral drive surface of the first staples todeploy the first staples from the first row of staple cavities. Thefirst ramp is configured to form the first staples against the first rowof pockets to a first formed height. The sled further comprises a secondramp configured to directly engage the integral drive surface of thesecond staples to deploy the second staples from the second row ofstaple cavities. The second ramp is configured to form the secondstaples against the second row of staple pockets to a second formedheight different than the first formed height.

Example 15

The surgical instrument of Example 14, wherein the second formed heightis greater than the first formed height.

Example 16

The surgical instrument of Examples 14 or 15, wherein the integral drivesurface is positioned intermediate the first leg and the second leg.

Example 17

The surgical instrument of Examples 14, 15, or 16, wherein the first legand the second leg define a leg plane, wherein the integral drivesurface defines a drive plane, and wherein the drive plane is offsetfrom the leg plane.

Example 18

The surgical instrument of Examples 14, 15, 16, or 17, wherein the baseis asymmetrical.

Example 19

The surgical instrument of Examples 14, 15, 16, 17, or 18, wherein thefirst ramp and the second ramp comprise different heights.

Example 20

The surgical instrument of Examples 14, 15, 16, 17, 18, or 19, whereinthe first ramp comprises a first peak surface, wherein the second rampcomprises a second peak surface, and wherein the first peak surface ishigher than the second peak surface.

Example 21

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody. The cartridge body comprises a proximal portion, a distal portion,and an elongate slot extending between the proximal portion and thedistal portion. The cartridge body also comprises a bottom surface, anda cartridge deck on an opposite side of the cartridge body from thebottom surface. The cartridge deck comprises a first deck surface, asecond deck surface laterally offset from the first deck surface in adirection away from the elongate slot, wherein the first deck surface isstepped up from the second deck surface relative to the bottom surface.The cartridge deck also comprises a third deck surface laterally offsetfrom the second deck surface in a direction away from the elongate slot,wherein the second deck surface is stepped up from the third decksurface relative to the bottom surface. The staple cartridge alsocomprises a plurality of staple cavities. The plurality of staplecavities comprise a first row of staple cavities defined in the firstdeck surface, and a second row of staple cavities defined in the seconddeck surface, wherein the first row of staple cavities is closer to theelongate slot than the second row of staple cavities. The plurality ofstaple cavities further comprise a third row of staple cavities definedin the third deck surface, wherein the second row of staple cavities iscloser to the elongate slot than the third row of staple cavities. Thestaple cartridge also comprises a plurality of staples housed in thecartridge body, wherein the plurality of staples comprises first staplesdeployable from the first row of staple cavities, second staplesdeployable from the second row of staple cavities, and third staplesdeployable from the third row of staple cavities. The staple cartridgefurther comprises tissue retention features defining a perimeter aroundthe plurality of staple cavities, wherein the tissue retention featuresprotrude from at least two of the first deck surface, the second decksurface, and the third deck surface.

Example 22

The staple cartridge assembly of Example 21, wherein the tissueretention features protrude from the first deck surface, the second decksurface, and the third deck surface.

Example 23

The staple cartridge assembly of Example 21, wherein the cartridge deckis free from the tissue retention features in areas between theplurality of staple cavities.

Example 24

The staple cartridge assembly of Examples 21 or 22, wherein each of thetissue retention features comprises a base defined in the cartridgedeck, and a peak narrower than the base.

Example 25

The staple cartridge assembly of Examples 21, 22, or 24, wherein thethird deck surface comprises more of the retention features than thesecond deck surface.

Example 26

The staple cartridge assembly of Examples 21, 22, or 24 wherein thefirst deck surface comprises more of the retention features than thesecond deck surface.

Example 27

The staple cartridge assembly of Examples 21, 22, 24, 25, or 26, whereinthe tissue retention members are comprised of an elastomer.

Example 28

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody comprising a proximal portion, a distal portion, and an elongateslot extending between the proximal portion and the distal portion. Thecartridge body further comprises a cartridge deck comprising a firstdeck surface defining a first deck height, and a second deck surfacedefining a second deck height, wherein the second deck surface islaterally offset from the first deck surface in a direction away fromthe elongate slot, and wherein the second deck height is shorter thanthe first deck height. The staple cartridge also comprises a pluralityof staple cavities comprising a first row of staple cavities defined inthe first deck surface, and a second row of staple cavities defined inthe second deck surface, wherein the first row of staple cavities iscloser to the elongate slot than the second row of staple cavities. Thestaple cartridge also comprises a plurality of staples housed in thecartridge body, the plurality of staples comprising first staplesdeployable from the first row of staple cavities into tissue, and secondstaples deployable from the second row of staple cavities into thetissue. The staple cartridge further comprises cleats configured toresist movement of the tissue relative to the cartridge deck, whereinthe cleats comprise first cleats extending from the first deck surface,wherein each of the first cleats comprises a first cleat height, andsecond cleats extending from the second deck surface. The second cleatsare laterally offset from the first cleats in a direction away from theelongate slot, wherein each of the second cleats comprises a secondcleat height, and wherein the first cleat height is different than thesecond cleat height.

Example 29

The staple cartridge assembly of Example 28, wherein the cartridge deckcomprises a third deck surface defining a third deck height, wherein thethird deck surface is laterally offset from the second deck surface in adirection away from the elongate slot, and wherein the third deck heightis shorter than the second deck height.

Example 30

The staple cartridge assembly of Examples 28 or 29, wherein the cleatscomprise third cleats extending from the third deck surface, and whereineach of the third cleats comprises a third cleat height, and wherein thesecond cleat height is shorter than the third cleat height.

Example 31

The staple cartridge assembly of Example 30, wherein the first cleatheight is shorter than the second cleat height.

Example 32

The staple cartridge assembly of Examples 28, 29, 30, or 31, wherein thesecond deck surface comprises more of the cleats than the first decksurface.

Example 33

The staple cartridge assembly of Examples 28, 29, 30, 31, or 32, whereineach of the cleats comprises a base defined in the cartridge deck, and apeak narrower than the base.

Example 34

The staple cartridge assembly of Example 33, wherein the peaks define aplane substantially parallel to the cartridge deck.

Example 35

The staple cartridge assembly of Examples 28, 29, 30, 31, 32, 33, or 34,wherein the cleats are comprised of an elastomer.

Example 36

A surgical stapling instrument, comprising an anvil and a staplecartridge. The anvil comprises a first row of pockets, and a second rowof pockets, and at least one of the anvil and the staple cartridge ismovable relative to the other between an open configuration and a closedconfiguration to capture tissue. The staple cartridge comprises acartridge body, a plurality of staple cavities, a plurality of staples,and transverse gap-setting members. The cartridge body comprises aproximal portion, a distal portion, an intermediate portion between theproximal portion and the distal portion, and an elongate slot extendingbetween the proximal portion and the distal portion. The cartridge bodyfurther comprises a cartridge deck comprising a first deck surface, anda second deck surface positioned further away from the elongate slotthan the first deck surface. The plurality of staple cavities comprisesa first row of staple cavities defined in the first deck surface,wherein a first gap is defined between the first row of pockets and thefirst row of staple cavities in the closed configuration. The pluralityof staple cavities further comprises a second row of staple cavitiesdefined in the second deck surface, wherein the first row of staplecavities is closer to the elongate slot than the second row of staplecavities, wherein a second gap is defined between the second row ofpockets and the second row of staple cavities in the closedconfiguration, and wherein the second gap is greater than the first gap.The plurality of staples is housed in the cartridge body, and comprisesfirst staples deployable from the first row of staple cavities into thetissue, and second staples deployable from the second row of staplecavities into the tissue. The transverse gap-setting members comprise afirst transverse gap-setting member at the proximal portion, wherein thefirst transverse gap-setting member comprises a first height. Thetransverse gap-setting members also comprise a second transversegap-setting member at the intermediate portion, wherein the secondtransverse gap-setting member comprises a second height greater than thefirst height. The transverse gap-setting members further comprise athird transverse gap-setting member at the distal portion, wherein thethird transverse gap-setting member comprises a third height greaterthan the second height.

Example 37

The surgical instrument of Example 36, wherein the transversegap-setting members extend across the elongate slot.

Example 38

The surgical instrument of Examples 36 or 37, wherein each of thetransverse gap-setting members comprises a base defined in the cartridgedeck, and a peak narrower than the base.

Example 39

The surgical instrument of Examples 36, 37, or 38, wherein thetransverse gap-setting members are comprised of an elastomer.

Example 40

The surgical instrument of Examples 36, 37, 38, or 39, wherein the firsttransverse gap-setting member is positioned proximal to the plurality ofstaple cavities, and wherein the third transverse gap-setting member ispositioned distal to the plurality of staple cavities.

Example 41

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody. The cartridge body comprises a proximal portion, a distal portion,an elongate slot extending between the proximal portion and the distalportion, and a bottom surface. The cartridge body also comprises acartridge deck on an opposite side of the cartridge body from the bottomsurface. The cartridge deck comprises a first deck surface, and a seconddeck surface laterally offset from the first deck surface in a directionaway from the elongate slot, wherein the first deck surface is steppedup from the second deck surface relative to the bottom surface. Thecartridge body also comprises staple pockets on opposite sides of theelongate slot, wherein the staple pockets comprise deformable retentionfeatures. The staple cartridge also comprises staples deployable fromthe staple pockets into tissue captured between the cartridge deck andthe anvil. The staple cartridge further comprises staple drivers movablefrom a starting position to deploy the staples into the tissue, whereinthe deformable retention features are configured to maintain the stapledrivers at the starting positions.

Example 42

The staple cartridge assembly of Example 41, wherein the deformableretention features are deformable retention ribs.

Example 43

The staple cartridge assembly of Examples 41 or 42, wherein thedeformable retention ribs comprise interference portions.

Example 44

The staple cartridge assembly of Examples 41, 42, or 43, wherein thestaple drivers comprise clearance slots configured to receive thedeformable retention features.

Example 45

The staple cartridge assembly of Examples 41, 42, 43, or 44, furthercomprising a sled configured to move the staple drivers from thestarting position by applying a deployment force to the staple driverssufficient to deform the deformable retention features.

Example 46

The staple cartridge assembly of Examples 41, 42, 43, 44, or 45, whereinthe staples are integral with the staple drivers.

Example 47

The staple cartridge assembly of Examples 41, 42, 43, 44, 45, or 46,wherein the deformable retention features are configured to maintain thestaple drivers at the starting position in absence of the bottomsurface.

Example 48

The staple cartridge assembly of Examples 41, 42, 43, 44, 45, 46, or 47,wherein the staple pockets comprise side walls, and wherein thedeformable retention features protrude from the side walls.

Example 49

The staple cartridge assembly of Example 48, wherein the deformableretention features are more flexible than the side walls.

Example 50

The staple cartridge assembly of Examples 48 or 49, wherein thedeformable retention features comprise a different material compositionthat the side walls.

Example 51

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody. The cartridge body comprises a proximal portion, a distal portion,an elongate slot extending between the proximal portion and the distalportion, and a bottom surface. The cartridge body also comprises acartridge deck on an opposite side of the cartridge body from the bottomsurface. The cartridge deck comprises a first deck surface, and a seconddeck surface laterally offset from the first deck surface in a directionaway from the elongate slot, wherein the first deck surface is furtheraway from the second deck surface relative to the bottom surface. Thecartridge body further comprises staple pockets on opposite sides of theelongate slot. The staple cartridge also comprises staples deployablefrom the staple pockets into tissue captured between the cartridge deckand the anvil. The staple cartridge further comprises staple driversmovable from a starting position to deploy the staples into the tissue,wherein the staple drivers comprise deformable retention featuresconfigured to maintain the staple drivers at the starting positions.

Example 52

The staple cartridge assembly of Example 51, wherein the deformableretention features are deformable retention ribs.

Example 53

The staple cartridge assembly of Examples 51 or 52, further comprising asled configured to move the staple drivers from the starting position byapplying a deployment force to the staple drivers sufficient to deformthe deformable retention features.

Example 54

The staple cartridge assembly of Examples 51, 52, or 53, wherein thedeformable retention features are integral with the staple drivers.

Example 55

The staple cartridge assembly of Examples 51, 52, 53, or 54, wherein thestaples are integral with the staple drivers.

Example 56

The staple cartridge assembly of Examples 51, 52, 53, 54, or 55, whereinthe deformable retention features are configured to maintain the stapledrivers at the starting position in absence of the bottom surface.

Example 57

The staple cartridge assembly of Examples 51, 52, 53, 54, 55, or 56,wherein the staple drivers comprise side walls, and wherein thedeformable retention features protrude from the side walls.

Example 58

The staple cartridge assembly of Example 57, wherein the deformableretention features are more flexible than the side walls.

Example 59

The staple cartridge assembly of Examples 57 or 58, wherein thedeformable retention features comprise a different material compositionthat the side walls.

Example 60

A staple cartridge assembly for use with a surgical stapling instrumentincluding an anvil, wherein the staple cartridge comprises a cartridgebody. The cartridge body comprises a proximal portion, a distal portion,and an elongate slot extending between the proximal portion and thedistal portion. The cartridge body also comprises a bottom surface, acartridge deck on an opposite side of the cartridge body from the bottomsurface, and staple pockets on opposite sides of the elongate slot. Thestaple cartridge also comprises staples deployable from the staplepockets into tissue captured between the cartridge deck and the anvil.The staple cartridge further comprises staple drivers movable from astarting position to deploy the staples into the tissue, wherein thestaple drivers comprise a quadruple staple driver. The quadruple stapledriver comprises pushers configured to simultaneously deploy four of thestaples into the tissue, wherein the pushers comprise side walls, anddeformable retention features protruding from the side walls, whereinthe deformable retention features cooperate to maintain the quadruplestaple driver at the starting position.

Example 61

A surgical instrument comprising a staple firing member and an endeffector. The staple firing member comprises a cutting member and anengagement member. The engagement member comprises a first engagementportion protruding in a first direction and a second engagement portionprotruding in a second direction opposite the first direction. The endeffector comprises a staple cartridge comprising a plurality of staplesand an anvil, wherein at least one of the staple cartridge and the anvilis movable to capture tissue between the staple cartridge and the anvil.The anvil comprises a first forming portion, comprising a first outerinterface comprising first staple forming pockets and a first innerinterface and a second forming portion spaced apart from the firstforming portion. The second forming portion comprises a second outerinterface comprising second staple forming pockets and a second innerinterface. The anvil further comprises an anvil channel, wherein thestaple firing member is advanced along the anvil channel to cause theplurality of staples to be deployed into the tissue and to be deformedagainst the first staple forming pockets and the second staple formingpockets. The anvil channel comprises an elongate slot inwardly openalong a longitudinal axis of the anvil, wherein the elongate slotextends longitudinally between the first forming portion and the secondforming portion. The anvil channel further comprises a first recessextending longitudinally adjacent the first inner interface, wherein thefirst recess is sized to receive the first engagement portion and asecond recess extending longitudinally adjacent the second innerinterface, wherein the second recess is sized to receive the secondengagement portion. The anvil further comprises a first reinforcementmember attached to the first inner interface, wherein the firstengagement portion is configured to slidingly engage the firstreinforcement member during the advancement of the staple firing memberand a second reinforcement member attached to the second innerinterface, wherein the elongate slot extends longitudinally between thefirst reinforcement member and the second reinforcement member. Thesecond reinforcement member is configured to engage the secondreinforcement member during the advancement of the staple firing member.

Example 62

The surgical instrument of Example 61, wherein the first reinforcementmember has a different material composition than the first formingportion.

Example 63

The surgical instrument of Examples 61 or 62, wherein the firstreinforcement member is harder than the first forming portion.

Example 64

The surgical instrument of Examples 61, 62, or 63, wherein the secondreinforcement member has a different material composition than thesecond forming portion.

Example 65

The surgical instrument of Examples 61, 62, 63, or 64, wherein thesecond reinforcement member is harder than the second forming portion.

Example 66

The surgical instrument of Examples 61, 62, 63, 64, or 65, wherein thefirst reinforcement member is welded to the first inner interface, andwherein the second reinforcement member is welded to the second innersurface.

Example 67

The surgical instrument of Examples 61, 62, 63, 64, 65, or 66, whereinthe anvil further comprises an anvil cover welded to the first formingportion and the second forming portion.

Example 68

A surgical instrument comprising an end effector transitionable betweenan open configuration and a closed configuration and a firing assembly.The end effector comprises a staple cartridge comprising a plurality ofstaples and an anvil comprising a plurality of staple forming pockets,wherein at least one of the staple cartridge and the anvil is movable tocapture tissue between the staple cartridge and the anvil. The firingassembly is movable to cause the plurality of staples to be deployedinto the tissue and to be deformed against the plurality of stapleforming pockets. The firing assembly comprises a firing member and alaminated firing bar extending proximally from the firing member. Thefiring member comprises a cutting edge, a first engagement memberconfigured to movably engage the anvil, and a second engagement memberconfigured to movably engage the staple cartridge, wherein the firstengagement member and the second engagement member cooperate totransition the end effector to the closed configuration. The laminatedfiring bar comprises a first outer layer, a second outer layer, and anintermediate layer sandwiched between the first outer layer and thesecond outer layer, wherein the intermediate layer is thicker than thefirst outer layer, and wherein the intermediate layer is thicker thanthe second outer layer.

Example 69

The surgical instrument of Example 68, wherein the intermediate layercomprises a different material composition than at least one of thefirst outer layer and the second.

Example 70

The surgical instrument of Examples 68 or 69, wherein the intermediatelayer is at least partially made from titanium.

Example 71

The surgical instrument of Examples 68, 69, or 70, wherein at least oneof the first outer layer and the second outer layer is at leastpartially made from stainless steel.

Example 72

The surgical instrument of Examples 68, 69, 70, or 71, wherein thelaminated firing bar comprises a transverse aperture extending throughthe first outer layer, the intermediate layer, and the second outerlayer, wherein the transverse aperture is at least partially filled withmelted portions of at least one of the first outer layer and the secondouter layer.

Example 73

The surgical instrument of Example 72, wherein the melted portionsextend through the intermediate layer.

Example 74

The surgical instrument of Examples 68, 69, 70, or 71, wherein thelaminated firing bar comprises a transverse aperture extending throughthe first outer layer, the intermediate layer, and the second outerlayer, wherein the transverse aperture is at least partially filled witha filler material configured to weld the intermediate layer to the firstouter layer and the second outer layer.

Example 75

The surgical instrument of Example 74, wherein at least one of the firstouter layer and the second outer layer is at least partially made fromthe filler material.

Example 76

A surgical instrument comprising an end effector transitionable betweenan open configuration and a closed configuration and a firing assembly.The end effector comprises a staple cartridge comprising a plurality ofstaples and an anvil comprising a plurality of staple forming pockets,wherein at least one of the staple cartridge and the anvil is movable tocapture tissue between the staple cartridge and the anvil. The firingassembly is a firing assembly movable to cause the plurality of staplesto be deployed into the tissue and to be deformed against the pluralityof staple forming pockets. The firing assembly comprises a firing memberand a laminated firing bar extending proximally from the firing member.The firing member comprises a cutting edge, a first engagement memberconfigured to movably engage the anvil, and a second engagement memberconfigured to movable engage the staple cartridge, wherein the firstengagement member and the second engagement member cooperate totransition the end effector to the closed configuration. The laminatedfiring bar comprises a first outer layer, a second outer layer, and anintermediate layer sandwiched between the first outer layer and thesecond outer layer, wherein the intermediate layer is harder than thefirst outer layer, and wherein the intermediate layer is harder than thesecond outer layer.

Example 77

The surgical instrument of Example 76, wherein the laminated firing barcomprises a transverse aperture extending through the first outer layer,the intermediate layer, and the second outer layer, wherein thetransverse aperture is at least partially filled with melted portions ofat least one of the first outer layer and the second outer layer.

Example 78

The surgical instrument of Example 77, wherein the melted portionsextend through the intermediate layer.

Example 79

The surgical instrument of Example 76, wherein the laminated firing barcomprises a transverse aperture extending through the first outer layer,the intermediate layer, and the second outer layer, wherein thetransverse aperture is at least partially filled with a filler materialconfigured to weld the intermediate layer to the first outer layer andthe second outer layer.

Example 80

The surgical instrument of Example 79, wherein at least one of the firstouter layer and the second outer layer is at least partially made fromthe filler material.

Example 81

An end effector for use with a surgical instrument, wherein the endeffector comprises a shaft portion, an anvil extending distally from theshaft portion, a staple cartridge comprising a plurality of staples, anelongate channel, and a firing member. The elongate channel isconfigured to receive the staple cartridge, wherein the elongate channelis movable relative to the anvil between an open configuration and aclosed configuration to capture tissue between the anvil and the staplecartridge. The firing member is configured to cause the plurality ofstaples to be deployed into the tissue, wherein the firing member ismovable distally to positively transition the elongate channel to aclosed configuration, and wherein the firing member is movableproximally to positively transition the elongate channel to the openconfiguration.

Example 82

The end effector of Example 81, wherein the anvil is fixedly attached tothe shaft portion.

Example 83

The end effector of Examples 81 or 82, further comprising a pivot,wherein the elongate channel is rotatable about the pivot.

Example 84

The end effector of Example 83, wherein the elongate channel comprises achannel hook movably coupled to the pivot.

Example 85

The end effector of Examples 81, 82, 83, or 84, wherein the staplecartridge is removably attached to the elongate channel.

Example 86

The end effector of Examples 81, 82, 83, 84, or 85, wherein the staplecartridge comprises a stepped deck.

Example 87

The end effector of Examples 81, 82, 83, 84, 85, or 86, wherein thefiring member comprises a cutting edge.

Example 88

An end effector for use with a surgical instrument, wherein the endeffector comprises a shaft portion, an anvil extending distally from theshaft portion, a staple cartridge comprising a plurality of staples, anelongate channel, and a firing member. The elongate channel isconfigured to receive the staple cartridge, wherein the elongate channelis movable relative to the anvil between an open configuration and aclosed configuration to capture tissue between the anvil and the staplecartridge. The firing member is movable relative to the elongate channelto cause the plurality of staples to be deployed into the tissue,wherein the firing member is configured to apply a closing force thattransitions the elongate channel to the closed configuration, andwherein the firing member is configured to apply an opening force thattransitions the elongate channel to the open configuration.

Example 89

The end effector of Example 88, wherein the anvil is fixedly attached tothe shaft portion.

Example 90

The end effector of Examples 88 or 89, further comprising a pivot,wherein the elongate channel is rotatable about the pivot.

Example 91

The end effector of Example 90, wherein the elongate channel comprises achannel hook movably coupled to the pivot.

Example 92

The end effector of Examples 88, 89, 90, or 91, wherein the staplecartridge is removably attached to the elongate channel.

Example 93

The end effector of Examples 88, 89, 90, 91, or 92, wherein the staplecartridge comprises a stepped deck.

Example 94

The end effector of Examples 88, 89, 90, 91, 92, or 93, wherein thefiring member comprises a cutting edge.

Example 95

An end effector for use with a surgical instrument, wherein the endeffector comprises a shaft portion, an anvil extending distally from theshaft portion, a staple cartridge comprising a plurality of staples, andan elongate channel. The end effector further comprises an opening cammovably engaged with the elongate channel, a firing member, and a firingbar. The elongate channel is configured to receive the staple cartridge,wherein the elongate channel is movable relative to the anvil between anopen configuration and a closed configuration to capture tissue betweenthe anvil and the staple cartridge. The firing member is movablerelative to the elongate channel to cause the plurality of staples to bedeployed into the tissue. The firing bar extends proximally from thefiring member, wherein a retraction of the firing bar moves the openingcam to positively open the elongate channel.

Example 96

The end effector of Example 95, wherein the anvil is fixedly attached tothe shaft portion.

Example 97

The end effector of Examples 95 or 96, further comprising a channelpivot, wherein the elongate channel is rotatable about the channelpivot.

Example 98

The end effector of Example 97, wherein the opening cam is positionedproximal to the channel pivot.

Example 99

The end effector of Examples 95, 96, 97, or 98, further comprising a campivot, wherein the opening cam is rotatable about the cam pivot.

Example 100

The end effector of Example 99, wherein the cam pivot is positionedproximal to the channel pivot.

Example 101

A disposable loading unit for use with a surgical instrument, whereinthe disposable loading unit comprises an end effector and a connectorportion extending proximally from the end effector. The end effectorcomprises an anvil, an elongate channel, and a staple cartridgeremovably coupled to the elongate channel, wherein at least one of theanvil and the elongate channel is movable to capture tissue between theanvil and the staple cartridge. The connector portion comprises a hollowbody defining a longitudinal axis therethrough. The hollow bodycomprises a first body portion on a first side of a plane transectingthe hollow body, wherein the plane encompasses the longitudinal axis, asecond body portion on a second side of the plane, and a plurality ofconnectors. The plurality of connectors comprise a first connectorprotruding from the first body portion, a second connector protrudingfrom the first body portion, a third connector protruding from thesecond body portion, and a fourth connector protruding from the secondbody portion, wherein the plurality of connectors cooperate toreleasably connect the disposable loading unit to the surgicalinstrument.

Example 102

The disposable loading unit of Example 101, wherein the first connectorand the third connector define a first axis transecting the longitudinalaxis.

Example 103

The disposable loading unit of Example 102, wherein the first axis isperpendicular to the longitudinal axis.

Example 104

The disposable loading unit of Examples 102 or 103, wherein the secondconnector and the fourth connector define a second axis transecting thelongitudinal axis.

Example 105

The disposable loading unit of Example 104, wherein the second axis isparallel to the first axis.

Example 106

The disposable loading unit of Example 104, wherein the second axis isperpendicular to the longitudinal axis.

Example 107

The disposable loading unit of Example 101, 102, 103, 104, 105, or 106,wherein the first connector is spaced apart from the second connector bya first distance, and wherein the third connector is spaced apart fromthe fourth connector by a second distance.

Example 108

The disposable loading unit of Example 107, wherein the first distanceis equal to the second distance.

Example 109

A disposable loading unit for use with a surgical instrument, whereinthe disposable loading unit comprises an end effector and a connectorportion extending proximally from the end effector. The end effectorcomprises an anvil, an elongate channel, and a staple cartridgeremovably coupled to the elongate channel, wherein at least one of theanvil and the elongate channel is movable to capture tissue between theanvil and the staple cartridge. The connector portion extends proximallyfrom the end effector. The connector portion comprises a hollow bodydefining a longitudinal axis therethrough. The hollow body comprises afirst engagement portion and a second engagement portion. The firstengagement portion comprises a first connector protruding from thehollow body and a second connector protruding from the hollow body in adirection away from the first connector. The second engagement portioncomprises a third connector protruding from the hollow body and a fourthconnector protruding from the hollow body in a direction away from thethird connector, wherein the first engagement portion is radially offsetfrom the second engagement portion, and wherein the first engagementportion and the second engagement portion cooperate to releasablyconnect the disposable loading unit to the surgical instrument.

Example 110

The disposable loading unit of Example 109, wherein the first engagementportion is oriented at a 90° angle with respect to the second engagementportion.

Example 111

The disposable loading unit of Examples 109 or 110, wherein the firstengagement portion defines a first axis transecting the longitudinalaxis.

Example 112

The disposable loading unit of Example 111, wherein the first axis isperpendicular to the longitudinal axis.

Example 113

The disposable loading unit of Examples 111 or 112, wherein the secondengagement portion defines a second axis transecting the longitudinalaxis.

Example 114

The disposable loading unit of Example 113, wherein the second axis isperpendicular to the longitudinal axis.

Example 115

The disposable loading unit of Examples 109, 110, 111, 112, 113, or 114,wherein the first engagement portion is spaced apart from the secondengagement portion.

Example 116

A disposable loading unit for use with a surgical instrument, whereinthe disposable loading unit comprises an end effector and a connectorportion extending proximally from the end effector. The end effectorcomprises an anvil, an elongate channel, and a staple cartridgeremovably coupled to the elongate channel, wherein at least one of theanvil and the elongate channel is movable to capture tissue between theanvil and the staple cartridge. The connector portion comprises atubular member, wherein the tubular member comprises an outer wall, afirst coupling flange, and a second coupling flange. The outer wallcomprises a first portion and a second portion radially offset from thefirst portion. The first coupling flange is radially disposed on thefirst portion of the outer wall. The second coupling flange is radiallydisposed on the second portion of the outer wall, wherein the firstcoupling flange and the second coupling flange cooperate to releasablyconnect the disposable loading unit to the surgical instrument.

Example 117

The disposable loading unit of Example 116, wherein the first couplingflange comprises a first distal portion, wherein the second couplingflange comprises a second distal portion, and wherein the first distalportion is positioned distally with respect to the second distalportion.

Example 118

The disposable loading unit of Examples 116 or 117, wherein the firstcoupling flange comprises a first proximal portion, wherein the secondcoupling flange comprises a second proximal portion, and wherein thefirst proximal portion is positioned proximally with respect to thesecond proximal portion.

Example 119

The disposable loading unit of Examples 116, 117, or 118, wherein thefirst coupling flange is spaced apart from the second coupling flange.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

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U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING ANDFASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued onSep. 9, 2008;

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U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FORA SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, nowU.S. Pat. No. 7,980,443;

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICALCUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM,now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVENSURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROLASSEMBLY, filed Dec. 24, 2009; now U.S. Pat. No. 8,220,688;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE,filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;

U.S. patent application Ser. No. 13/036,647, entitled SURGICAL STAPLINGINSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No. 8,561,870;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat.No. 9,072,535;

U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012;now U.S. Pat. No. 9,101,358;

U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Pat.No. 9,345,481;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGETISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. PatentApplication Publication No. 2014/0263552;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICALCUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM,filed Jan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICALSTAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22,2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by referenceherein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical instrument, comprising: a staplefiring member, comprising: a cutting member; and an engagement member,comprising: a first engagement portion protruding in a first direction;and a second engagement portion protruding in a second directionopposite the first direction; and an end effector, comprising: a staplecartridge comprising a plurality of staples; and an anvil, wherein atleast one of the staple cartridge and the anvil is movable to capturetissue between the staple cartridge and the anvil, and wherein the anvilcomprises: a first forming portion, comprising: a first outer interfacecomprising first staple forming pockets; and a first inner interface; asecond forming portion spaced apart from the first forming portion,wherein the second forming portion comprises: a second outer interfacecomprising second staple forming pockets; and a second inner interface;an anvil channel, wherein the staple firing member is advanced along theanvil channel to cause the plurality of staples to be deployed into thetissue and to be deformed against the first staple forming pockets andthe second staple forming pockets, and wherein the anvil channelcomprises: an elongate slot inwardly open along a longitudinal axis ofthe anvil, wherein the elongate slot extends longitudinally between thefirst forming portion and the second forming portion; a first recessextending longitudinally adjacent the first inner interface, wherein thefirst recess is sized to receive the first engagement portion; and asecond recess extending longitudinally adjacent the second innerinterface, wherein the second recess is sized to receive the secondengagement portion; a first reinforcement member attached to the firstinner interface, wherein the first engagement portion is configured toslidingly engage the first reinforcement member during the advancementof the staple firing member; and a second reinforcement member attachedto the second inner interface, wherein the elongate slot extendslongitudinally between the first reinforcement member and the secondreinforcement member; and wherein the second reinforcement member isconfigured to engage the second reinforcement member during theadvancement of the staple firing member.
 2. The surgical instrument ofclaim 1, wherein the first reinforcement member has a different materialcomposition than the first forming portion.
 3. The surgical instrumentof claim 2, wherein the first reinforcement member is harder than thefirst forming portion.
 4. The surgical instrument of claim 3, whereinthe second reinforcement member has a different material compositionthan the second forming portion.
 5. The surgical instrument of claim 4,wherein the second reinforcement member is harder than the secondforming portion.
 6. The surgical instrument of claim 5, wherein thefirst reinforcement member is welded to the first inner interface, andwherein the second reinforcement member is welded to the second innersurface.
 7. The surgical instrument of claim 1, wherein the anvilfurther comprises an anvil cover welded to the first forming portion andthe second forming portion.
 8. A surgical instrument, comprising: an endeffector transitionable between an open configuration and a closedconfiguration, wherein the end effector comprises: a staple cartridgecomprising a plurality of staples; and an anvil comprising a pluralityof staple forming pockets, wherein at least one of the staple cartridgeand the anvil is movable to capture tissue between the staple cartridgeand the anvil; and a firing assembly movable to cause the plurality ofstaples to be deployed into the tissue and to be deformed against theplurality of staple forming pockets, wherein the firing assemblycomprises: a firing member, comprising: a cutting edge; a firstengagement member configured to movably engage the anvil; and a secondengagement member configured to movably engage the staple cartridge,wherein the first engagement member and the second engagement membercooperate to transition the end effector to the closed configuration;and a laminated firing bar extending proximally from the firing member,wherein the laminated firing bar comprises: a first outer layer; asecond outer layer; and an intermediate layer sandwiched between thefirst outer layer and the second outer layer, wherein the intermediatelayer is thicker than the first outer layer, and wherein theintermediate layer is thicker than the second outer layer.
 9. Thesurgical instrument of claim 8, wherein the intermediate layer comprisesa different material composition than at least one of the first outerlayer and the second.
 10. The surgical instrument of claim 8, whereinthe intermediate layer is at least partially made from titanium.
 11. Thesurgical instrument of claim 10, wherein at least one of the first outerlayer and the second outer layer is at least partially made fromstainless steel.
 12. The surgical instrument of claim 8, wherein thelaminated firing bar comprises a transverse aperture extending throughthe first outer layer, the intermediate layer, and the second outerlayer, wherein the transverse aperture is at least partially filled withmelted portions of at least one of the first outer layer and the secondouter layer.
 13. The surgical instrument of claim 12, wherein the meltedportions extend through the intermediate layer.
 14. The surgicalinstrument of claim 8, wherein the laminated firing bar comprises atransverse aperture extending through the first outer layer, theintermediate layer, and the second outer layer, wherein the transverseaperture is at least partially filled with a filler material configuredto weld the intermediate layer to the first outer layer and the secondouter layer.
 15. The surgical instrument of claim 14, wherein at leastone of the first outer layer and the second outer layer is at leastpartially made from the filler material.
 16. A surgical instrument,comprising: an end effector transitionable between an open configurationand a closed configuration, wherein the end effector comprises: a staplecartridge comprising a plurality of staples; and an anvil comprising aplurality of staple forming pockets, wherein at least one of the staplecartridge and the anvil is movable to capture tissue between the staplecartridge and the anvil; and a firing assembly movable to cause theplurality of staples to be deployed into the tissue and to be deformedagainst the plurality of staple forming pockets, wherein the firingassembly comprises: a firing member, comprising: a cutting edge; a firstengagement member configured to movably engage the anvil; and a secondengagement member configured to movably engage the staple cartridge,wherein the first engagement member and the second engagement membercooperate to transition the end effector to the closed configuration;and a laminated firing bar extending proximally from the firing member,wherein the laminated firing bar comprises: a first outer layer; asecond outer layer; and an intermediate layer sandwiched between thefirst outer layer and the second outer layer, wherein the intermediatelayer is harder than the first outer layer, and wherein the intermediatelayer is harder than the second outer layer.
 17. The surgical instrumentof claim 16, wherein the laminated firing bar comprises a transverseaperture extending through the first outer layer, the intermediatelayer, and the second outer layer, wherein the transverse aperture is atleast partially filled with melted portions of at least one of the firstouter layer and the second outer layer.
 18. The surgical instrument ofclaim 17, wherein the melted portions extend through the intermediatelayer.
 19. The surgical instrument of claim 16, wherein the laminatedfiring bar comprises a transverse aperture extending through the firstouter layer, the intermediate layer, and the second outer layer, whereinthe transverse aperture is at least partially filled with a fillermaterial configured to weld the intermediate layer to the first outerlayer and the second outer layer.
 20. The surgical instrument of claim19, wherein at least one of the first outer layer and the second outerlayer is at least partially made from the filler material.